101608-6371 ZEXEL 9 400 619 505 BOSCH INJECTION-PUMP ASSEMBLY 9400619505 1016086371

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 505 9400619505

ZEXEL 101608-6371 1016086371

Service parts 101608-6371 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9290

3. GOVERNOR 105401-1271

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-1300

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6920

11. Nozzle and Holder ME440837

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

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-3120

15. NOZZLE SET

Include in #1:

101608-6371 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-0523 as _

Cross reference number

BOSCH 9 400 619 505 9400619505

ZEXEL 101608-6371 1016086371

Zexel num

Bosch num

Firm num

Name

101608-6371
101608-6372

9 400 619 505

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 131424-5520

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 3.5 3.45 3.55

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 A

Rack position 8.3

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8.5 7.2 9.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 8.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.9

Boost pressure kPa 30.7 25.4 36

Boost pressure mmHg 230 190 270

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(8.3)

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min 750+-25

Advance angle deg. 0 0 0

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=12 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Base lever only
----------

----------
a=4deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position = aa, speed = bb (stamp at delivery) (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(130deg)