101608-1291 ZEXEL 9 400 619 495 BOSCH INJECTION-PUMP ASSEMBLY 9400619495 1016081291


101608-1291 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 495 9400619495
ZEXEL 101608-1291 1016081291

Service parts 101608-1291 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8851
3. GOVERNOR 105932-1651
4. SUPPLY PUMP 105210-6020
5. AUTOM. ADVANCE MECHANIS 105672-5230
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-7183
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}
13. NOZZLE-HOLDER 105041-3031
14. NOZZLE
15. NOZZLE SET 105019-0371

Include in #1:

101608-1291 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 495 9400619495
ZEXEL 101608-1291 1016081291


Zexel num
Bosch num
Firm num
Name
101608-1291 
101608-1292 
9 400 619 495 
   
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   131424-8420
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Governor 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   11.9
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   81.5 79.1 83.9
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   9.5+-0.5
Pump speed r/min   600 600 600
Each cylinder's injection qty mm3/st.   10.8 9.2 12.4
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.9)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   81.5 80.5 82.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.35
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   88 84 92
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   59.5 55.5 63.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 85 105
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1 0.5 1.5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1100
Advance angle deg.   1 0.5 1.5
Timer adjustment_05
Pump speed r/min   1400
Advance angle deg.   7 6.5 7.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-1291
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L01
----------

Speed control lever angle

Test data 101608-1291
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101608-1291
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1450r/min bb=4.2-0.5mm cc=275r/min dd=(8.8)mm
----------
a=11.5deg+-5deg b=30deg+-5deg

0000001501 MICRO SWITCH

Adjust the bolt to obtain the following lever position when the micro-switch is ON. 1. Microswitch adjustment (OPEN type) Confirm with the lever angle at full. (1)Speed N1 (2)Rack position Ra 2. Idle side microswitch adjustment (OPEN type) Confirm with the lever angle at idle. (1)Speed N2 (2)Rack position Rb
----------
N1=1660r/min Ra=9.2+-0.1mm N2=285r/min Rb=10.2+-0.1mm
----------

0000001601 RACK SENSOR

Test data 101608-1291
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

0000001701 LEVER

Test data 101608-1291
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=42deg+-3deg c=18.5deg+-5deg

Timing setting

Test data 101608-1291
(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=7deg
----------
a=(4deg)




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