103662-3360 ZEXEL 9 400 611 949 BOSCH INJECTION-PUMP ASSEMBLY 9400611949 1036623360

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 949 9400611949

ZEXEL 103662-3360 1036623360

Service parts 103662-3360 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103066-8460

3. GOVERNOR 105455-1150

4. SUPPLY PUMP 105235-1781

5. AUTOM. ADVANCE MECHANIS 105649-0070

6. COUPLING PLATE 105664-0490

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4812

11. Nozzle and Holder 6162-13-8902

12. Open Pre:MPa(Kqf/cm2) 29.4{300}

13. NOZZLE-HOLDER 105041-7102

14. NOZZLE 105025-3010

15. NOZZLE SET

Include in #1:

101602-1530 as _

103662-3360 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 949 9400611949

ZEXEL 103662-3360 1036623360

Zexel num

Bosch num

Firm num

Name

103662-3360
103662-3361

9 400 611 949

INJECTION-PUMP ASSEMBLY
SA6D170 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve 131425-2020

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.8 3.75 3.85

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 18.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 499 494 504

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 92 92

Boost pressure mmHg 690 690

Injection quantity adjustment_02

Adjusting point B

Rack position 10.5+-0. 5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 44.5 39.5 49.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 485 485 505

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-4.4

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(18.3)

Boost pressure kPa 78.6 71.9 85.3

Boost pressure mmHg 590 540 640

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Boost compensator stroke: BCL (4)Stop lever at stopping (with the speed lever at full, 0 boost)
----------
K=19 BCL=4.4+-0.1mm
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Speed control lever angle

F:Full speed I:Idle S:Stop
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----------
a=37deg+-5deg b=28deg+-5deg c=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)The clearance from the set screw must be aa. (2)Use the hole at R = bb (3)Set the screw so that speed = cc, rack position = dd (4)At speed lever full, 0 boost
----------
aa=2+1mm bb=40mm cc=100r/min dd=5-0.2mm
----------
a=16deg+-5deg b=40deg+-5deg