101641-9030 ZEXEL 9 400 610 358 BOSCH INJECTION-PUMP ASSEMBLY 9400610358 1016419030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 358 9400610358

ZEXEL 101641-9030 1016419030

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Service parts 101641-9030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101064-9030

3. GOVERNOR 105931-0502

4. SUPPLY PUMP 105220-4860

5. AUTOM. ADVANCE MECHANIS 105622-0680

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1800

11. Nozzle and Holder 16600-90019

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1240

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101641-9030 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3653 as _

104740-3654

Cross reference number

BOSCH 9 400 610 358 9400610358

ZEXEL 101641-9030 1016419030

Zexel num

Bosch num

Firm num

Name

101641-9030
101641-9031

9 400 610 358

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

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 1-4-2-6- 3-5

Pre-stroke mm 2.3 2.25 2.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 38.4 37.3 39.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.05

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 37.8 35.8 39.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 11.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 34.6 33.6 35.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 9.05+-0. 5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 6.2 5.1 7.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 11.9

Boost pressure kPa 8.7 8.7 8.7

Boost pressure mmHg 65 65 65

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 12.4

Boost pressure kPa 19.3 16 22.6

Boost pressure mmHg 145 120 170

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

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_05

Pump speed r/min 1200

Advance angle deg. 2.5 2 3

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 7.5 7.5 7.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL (3)Boost compensator stroke: BCL
----------
T1=43 RAL=14.6+0.2mm BCL=0.5mm
----------

Speed control lever angle

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

----------
a=2deg+-5deg b=37deg+-3deg

Stop lever angle

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

----------
a=(6deg) b=(44deg)

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(130deg)

Information:

FEED ENGAGED
21. Slot. 22. Pin. 23. Knob. To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).
LATER FEED MECHANISM
A. Lever.Place adapter (24) into boring bar and tightening setscrew (25).
ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 .0005 in. (94.425 0.013 mm).
BORING BEARING BORE
26. 1P2363 Universal. If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.
DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.The bluing applied to the bearing bore indicates the condition of the bore at the corret bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).
CHECKING BORE (Typical Example)Line Boring Main Bearing Bores
Line bore all main bearing bores if bearing caps or saddles are distorted.Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore. There must be two good bores for locating centering rings.
CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.
CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.
BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N m) and a maximum of 50 lb. ft. (70 N m) while spinning bearing bar (5) to check for binding. Centering rings (1) must be seated in boring saddles after tightening.Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.
INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly