101401-1931 ZEXEL 9 400 613 416 BOSCH INJECTION-PUMP ASSEMBLY 9400613416 1014011931


101401-1931 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 416 9400613416
ZEXEL 101401-1931 1014011931

Include in #1:

Cross reference number

BOSCH 9 400 613 416 9400613416
ZEXEL 101401-1931 1014011931


Zexel num
Bosch num
Firm num
Name
101401-1931 
101401-1932 
9 400 613 416 
   
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   131424-4620
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.5 3.45 3.55
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   A
Rack position   10.4
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   96.5 95.5 97.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   39.3 39.3
Boost pressure mmHg   295 295
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.7+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   8 6.7 9.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   C
Rack position   10.6++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   155 155 160
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   800 800 800
Rack position   R1-0.3
Boost pressure kPa   13.3 6.6 20
Boost pressure mmHg   100 50 150
Boost compensator adjustment_02
Pump speed r/min   800 800 800
Rack position   R1(10.4)
Boost pressure kPa   30 27.3 32.7
Boost pressure mmHg   225 205 245
Timer adjustment
Pump speed r/min   0
Advance angle deg.   2.5 2 3
Timer adjustment_02
Pump speed r/min   (630)
Advance angle deg.   2.5 2 3
Remarks
Start
 
Timer adjustment_03
Pump speed r/min   720+-25
Advance angle deg.   0 0 0
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-1931
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=10 BCL=0.3+-0.1mm
----------

Speed control lever angle

Test data 101401-1931
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(6deg)+-5deg b=(18deg)+-5deg

Stop lever angle

Test data 101401-1931
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101401-1931
Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

Test data 101401-1931
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)




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