101608-6490 ZEXEL 9 400 619 516 BOSCH INJECTION-PUMP ASSEMBLY 9400619516 1016086490

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 516 9400619516

ZEXEL 101608-6490 1016086490

Service parts 101608-6490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6730

3. GOVERNOR 105411-2560

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105680-9050

6. COUPLING PLATE 105663-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5340

11. Nozzle and Holder ME441452

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

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-4020

15. NOZZLE SET

Include in #1:

101608-6490 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-0735 as _

Cross reference number

BOSCH 9 400 619 516 9400619516

ZEXEL 101608-6490 1016086490

Zexel num

Bosch num

Firm num

Name

101608-6490
101608-6491

9 400 619 516

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 255 255 255

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)
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 11.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 126 125 127

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Boost pressure kPa 52.7 52.7

Boost pressure mmHg 395 395

Injection quantity adjustment_02

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 350 350 350

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 D

Rack position 12.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115 125

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 9.8

Boost pressure kPa 9.3 6.6 12

Boost pressure mmHg 70 50 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 11.5

Boost pressure kPa 39.3 32.6 46

Boost pressure mmHg 295 245 345

Timer adjustment

Pump speed r/min [N1+50]- -

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min N1

Advance angle deg. 0.5

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 4/4

Remarks
Measure the actual speed, stop

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
----------
K=6 BCL=1.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)When pump speed set at bb (3)Stopper bolt setting
----------
aa=900r/min bb=755r/min
----------
a=20deg+-5deg b=9deg+-5deg c=6deg+-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)

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=7deg
----------
a=(3deg)