101608-6521 ZEXEL 9 400 619 712 BOSCH INJECTION-PUMP ASSEMBLY 9400619712 1016086521

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 712 9400619712

ZEXEL 101608-6521 1016086521

Service parts 101608-6521 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9290

3. GOVERNOR 105401-1410

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-1320

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:

101608-6521 as INJECTION-PUMP ASSEMBLY

Include in #2:

104700-0511 as _

Cross reference number

BOSCH 9 400 619 712 9400619712

ZEXEL 101608-6521 1016086521

Zexel num

Bosch num

Firm num

Name

101608-6521
101608-6522

9 400 619 712

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 255 221 289

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)
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 A

Rack position 9

Pump speed r/min 1085 1085 1085

Average injection quantity mm3/st. 95 94 96

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 80 80

Boost pressure mmHg 600 600

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 515 515 515

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

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 9.2++

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 900 900 900

Rack position R1-1.05

Boost pressure kPa 24 17.3 30.7

Boost pressure mmHg 180 130 230

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Rack position R1(9)

Boost pressure kPa 70.6 67.9 73.3

Boost pressure mmHg 530 510 550

Timer adjustment

Pump speed r/min 0

Advance angle deg. 3 2 3

Load 0/4

Timer adjustment_02

Pump speed r/min 650+-25

Advance angle deg. 3 2 3

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min 750+-25

Advance angle deg. 0 0 0

Load 0/4

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)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=13 BCL=1.05+-0.1mm
----------

Speed control lever angle

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

----------
a=4deg+-5deg b=18.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
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=10deg
----------
a=(130deg)