101691-9482 ZEXEL 9 400 619 524 BOSCH INJECTION-PUMP ASSEMBLY 9400619524 1016919482


101691-9482 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 524 9400619524
ZEXEL 101691-9482 1016919482

Service parts 101691-9482 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-8030
3. GOVERNOR 105472-1073
4. SUPPLY PUMP 105220-4080
5. AUTOM. ADVANCE MECHANIS 105622-1360
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5010
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105031-4840
14. NOZZLE 105015-6400
15. NOZZLE SET

Include in #1:

101691-9482 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 619 524 9400619524
ZEXEL 101691-9482 1016919482


Zexel num
Bosch num
Firm num
Name
101691-9482 
101691-9483 
9 400 619 524 
   
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   132424-0620
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

Test data 101691-9482
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting (6)Rack difference to N = N2
----------
RT=1 TH=2.3mm SXL=12.8+0.2mm N1=550r/min N2=1500r/min
----------

0000000901

Test data 101691-9482
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=33deg+-3deg

Stop lever angle

Test data 101691-9482
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101691-9482
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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