101608-6320 ZEXEL 9 400 619 502 BOSCH INJECTION-PUMP ASSEMBLY 9400619502 1016086320

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 502 9400619502

ZEXEL 101608-6320 1016086320

Service parts 101608-6320 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6730

3. GOVERNOR 105411-2330

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105680-9010

6. COUPLING PLATE 105663-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5190

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-3250

15. NOZZLE SET

Include in #1:

101608-6320 as INJECTION-PUMP ASSEMBLY

Include in #2:

104748-0530 as _

Cross reference number

BOSCH 9 400 619 502 9400619502

ZEXEL 101608-6320 1016086320

Zexel num

Bosch num

Firm num

Name

101608-6320
101608-6321

9 400 619 502

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 131424-5520

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.5 4.45 4.55

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 A

Rack position 11.1

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 107.5 106.5 108.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 65.3 65.3

Boost pressure mmHg 490 490

Injection quantity adjustment_02

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 495 495 495

Average injection quantity mm3/st. 16.5 15 18

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position 11.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 105 115

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 375 375 375

Rack position 9.5

Boost pressure kPa 24 17.3 30.7

Boost pressure mmHg 180 130 230

Boost compensator adjustment_02

Pump speed r/min 375 375 375

Rack position 10.4

Boost pressure kPa 56 53.3 58.7

Boost pressure mmHg 420 400 440

Timer adjustment

Pump speed r/min 600

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 720

Advance angle deg. 0.5

Load 0/4

Timer adjustment_03

Pump speed r/min (820)

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_04

Pump speed r/min 1000

Advance angle deg. 1.5 1 2

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=10 BCL=0.9+-0.1mm
----------

Speed control lever angle

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

----------
a=18deg+-5deg b=3deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

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=8deg
----------
a=(0deg)