101608-1332 ZEXEL 9 400 619 500 BOSCH INJECTION-PUMP ASSEMBLY 9400619500 1016081332

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 500 9400619500

ZEXEL 101608-1332 1016081332

Service parts 101608-1332 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9951

3. GOVERNOR 105921-8790

4. SUPPLY PUMP 105220-7120

5. AUTOM. ADVANCE MECHANIS 105672-0550

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6241

11. Nozzle and Holder ME086812

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

13. NOZZLE-HOLDER 105048-3501

14. NOZZLE 105017-2060

15. NOZZLE SET

Include in #1:

101608-1332 as INJECTION-PUMP ASSEMBLY

107692-1421 as _

Cross reference number

BOSCH 9 400 619 500 9400619500

ZEXEL 101608-1332 1016081332

Zexel num

Bosch num

Firm num

Name

101608-1332
101608-1333

9 400 619 500

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 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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

Overflow valve 131424-8820

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.2 3.15 3.25

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 11.2

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 69 67.4 70.6

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 Z

Rack position 8.8+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 17.5 16.2 18.8

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(11.2)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 69 68 70

Basic *

Fixing the lever *

Boost pressure kPa 36.7 36.7

Boost pressure mmHg 275 275

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 79 75 83

Fixing the lever *

Boost pressure kPa 36.7 36.7

Boost pressure mmHg 275 275

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-0.2

Boost pressure kPa 13.3 12 14.6

Boost pressure mmHg 100 90 110

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-0. 7)

Boost pressure kPa 23.3 23.3 23.3

Boost pressure mmHg 175 175 175

Timer adjustment

Pump speed r/min 1550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 2.5 2 3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=M06 BCL=0.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=23.5deg+-5deg b=(38.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=40mm
----------
a=33deg+-5deg b=40deg+-5deg

Timing setting

(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=12deg
----------
a=(2deg)