101691-9481 ZEXEL 9 400 619 558 BOSCH INJECTION-PUMP ASSEMBLY 9400619558 1016919481

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 558 9400619558

ZEXEL 101691-9481 1016919481

Service parts 101691-9481 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-8030

3. GOVERNOR 105472-1072

4. SUPPLY PUMP 105220-4080

5. AUTOM. ADVANCE MECHANIS 105622-1360

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101691-9481 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-8580 as _

104745-8581

104745-8582

Cross reference number

BOSCH 9 400 619 558 9400619558

ZEXEL 101691-9481 1016919481

Zexel num

Bosch num

Firm num

Name

101691-9481
101691-9482

9 400 619 558

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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-5-3-6- 2-4

Pre-stroke mm 2.2 2.15 2.25

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 11.7

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 65 63.5 66.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61 57 65

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.6+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60.5 60.5

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 2.7 2 3.4

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 4.4 3.7 5.1

Timer adjustment_06

Pump speed r/min 1500

Advance angle deg. 4.8 4.1 5.5

Timer adjustment_07

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (5)Rack difference from N = N1
----------
RT=1 TH=2.8mm SXL=12.8+0.2mm DL=5.9-0.2mm N1=1500r/min
----------

0000000901

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

----------
a=16deg+-5deg b=34.5deg+-5deg

Stop lever angle

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

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard installation threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)