101607-1491 ZEXEL 9 400 610 239 BOSCH INJECTION-PUMP ASSEMBLY 9400610239 1016071491


101607-1491 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 239 9400610239
ZEXEL 101607-1491 1016071491

Service parts 101607-1491 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9540
3. GOVERNOR 105921-5331
4. SUPPLY PUMP 105220-5150
5. AUTOM. ADVANCE MECHANIS 105672-0110
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4901
11. Nozzle and Holder ME086584
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105048-3590
14. NOZZLE 105017-0890
15. NOZZLE SET

Include in #1:

101607-1491 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 610 239 9400610239
ZEXEL 101607-1491 1016071491


Zexel num
Bosch num
Firm num
Name
101607-1491 
101607-1492 
9 400 610 239 
   
INJECTION-PUMP ASSEMBLY
* K 14BE PE6A PE

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   131424-6220
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   1-5-3-6- 2-4
Pre-stroke mm   3.3 3.25 3.35
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   11.5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   56.4 54.8 58
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   12.2 10.9 13.5
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   56.4 55.4 57.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   64.6 60.6 68.6
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.6
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   44.4 40.4 48.4
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   73 73 78
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1500+50
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1600
Advance angle deg.   1 0.5 1.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-1491
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G09
----------

Speed control lever angle

Test data 101607-1491
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(40.5deg)+-3deg

Stop lever angle

Test data 101607-1491
N:Pump normal S:Stop the pump. (1)Free (at shipping) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1600r/min dd=6.5-0.5mm ee=275r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

Timing setting

Test data 101607-1491
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(5deg)




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