101693-9560 ZEXEL 9 400 612 196 BOSCH INJECTION-PUMP ASSEMBLY 9400612196 1016939560

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 196 9400612196

ZEXEL 101693-9560 1016939560

Include in #1:

106691-2031 as _

Cross reference number

BOSCH 9 400 612 196 9400612196

ZEXEL 101693-9560 1016939560

Zexel num

Bosch num

Firm num

Name

101693-9560

9 400 612 196

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 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2.7 2 3.4

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 4.4 3.7 5.1

Timer adjustment_05

Pump speed r/min 1500

Advance angle deg. 4.8 4.1 5.5

Timer adjustment_06

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)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
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RT=1 TH=2.3mm SXL=12.8+0.2mm N1=550r/min N2=1500r/min
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Speed control lever angle

F:Full speed
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a=(10deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=16deg+-5deg b=32.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=20deg+-5deg b=71deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. 2. Adjustment following governor installation (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
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N1=1500r/min L1=(0.1~0.5)mm
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R1=11.7mm R2=(9.9)mm P1=(98)kPa((735)mmHg) P2=65.9+-0.7kPa(494+-5mmHg) Q1=65+-1.5cm3/1000st Q2=45.5+-1.5cm3/1000st

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)-
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a=(50deg)