101631-9880 ZEXEL 9 400 619 799 BOSCH INJECTION-PUMP ASSEMBLY 9400619799 1016319880

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 799 9400619799

ZEXEL 101631-9880 1016319880

Service parts 101631-9880 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101063-9390

3. GOVERNOR 105410-3990

4. SUPPLY PUMP 105220-4630

5. AUTOM. ADVANCE MECHANIS 105622-0250

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1800

11. Nozzle and Holder 1660090019

12. Open Pre:MPa(Kqf/cm2) 9.8(100)

13. NOZZLE-HOLDER 105071-1240

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101631-9880 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3500 as _

Cross reference number

BOSCH 9 400 619 799 9400619799

ZEXEL 101631-9880 1016319880

Zexel num

Bosch num

Firm num

Name

101631-9880
101631-9881

9 400 619 799

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

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 2.3 2.25 2.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 14.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 35.2 34.2 36.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 14.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 31.6 30.1 33.1

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 10.6+-0. 5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 7.5 6.4 8.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min (895)

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7.5 7.5 7.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=9deg+-5deg b=32deg+-5deg c=32deg+-3deg d=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=B a2=- r1=750r/min r2=- Q1=35.2+-1mm3/st Q2=- c1=+-2.5% c2=- a3=18 a4=15 r3=900r/min r4=750r/min