101606-9460 ZEXEL 9 400 619 555 BOSCH INJECTION-PUMP ASSEMBLY 9400619555 1016069460

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 555 9400619555

ZEXEL 101606-9460 1016069460

Service parts 101606-9460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5290

3. GOVERNOR 105482-7400

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105644-0530

6. COUPLING PLATE 105662-1400

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7550

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105030-4530

14. NOZZLE 105015-9480

15. NOZZLE SET

Include in #1:

101402-7103 as _

101606-9460 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 555 9400619555

ZEXEL 101606-9460 1016069460

Zexel num

Bosch num

Firm num

Name

101606-9460
101606-9461

9 400 619 555

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.3 4.25 4.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 7.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 96 94 98

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9+-0.5

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 105 99 111

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point E

Rack position 5.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 15 13 17

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 75 155

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1130--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1330

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Microswitch not operating at delivery. (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting
----------
RT=0.8 TH=1.5mm SXL=8.9+-0.1mm N1=400r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=(5.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=23deg+-5deg b=33.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Drive side
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(60deg)