101602-1590 ZEXEL 9 400 613 157 BOSCH INJECTION-PUMP ASSEMBLY 9400613157 1016021590


101602-1590 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 157 9400613157
ZEXEL 101602-1590 1016021590

Service parts 101602-1590 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8040
3. GOVERNOR 105411-2010
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156637-7220
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4850
11. Nozzle and Holder ME078538
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3350
14. NOZZLE 105025-1870
15. NOZZLE SET

Include in #1:

101602-1590 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 157 9400613157
ZEXEL 101602-1590 1016021590


Zexel num
Bosch num
Firm num
Name
101602-1590 
101602-1591 
9 400 613 157 
   
INJECTION-PUMP ASSEMBLY
6D16T * K 14BF PE6AD PE

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   131424-5620
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)
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   4.5 4.45 4.55
Beginning of injection position
Governor 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   9.6
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   122 118.5 125.5
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Boost pressure kPa   53.3 53.3
Boost pressure mmHg   400 400
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.6+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   10.5 9 12
Max. variation between cylinders %   0 -15 15
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.
 
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R1-0.75
Boost pressure kPa   28 25.3 30.7
Boost pressure mmHg   210 190 230
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   R1(9.6)
Boost pressure kPa   40 33.3 46.7
Boost pressure mmHg   300 250 350

Test data Ex:

Governor adjustment

Test data 101602-1590
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2 (5)Set idle sub-spring
----------
K=16 BCL=0.75+-0.1mm N1=750r/min N2=250r/min
----------

Speed control lever angle

Test data 101602-1590
F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=22deg+-5deg b=1deg+-5deg c=6deg+-5deg

Stop lever angle

Test data 101602-1590
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Seal at delivery.)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101602-1590
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(0.30~0.45kgf-m)
----------

Timing setting

Test data 101602-1590
(1)Pump vertical direction (2)Position of coupling's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(1deg)




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