101603-2332 ZEXEL 9 400 610 645 BOSCH INJECTION-PUMP ASSEMBLY 9400610645 1016032332


101603-2332 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 645 9400610645
ZEXEL 101603-2332 1016032332

Service parts 101603-2332 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5310
3. GOVERNOR 105401-0842
4. SUPPLY PUMP 105210-5570
5. AUTOM. ADVANCE MECHANIS 105672-0560
6. COUPLING PLATE 105662-1160
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4100
11. Nozzle and Holder 23600-2710A
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-4440
14. NOZZLE 105015-9220
15. NOZZLE SET

Include in #1:

101603-2332 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 645 9400610645
ZEXEL 101603-2332 1016032332


Zexel num
Bosch num
Firm num
Name
101603-2332 
101603-2333 
9 400 610 645 
   
INJECTION-PUMP ASSEMBLY
* 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   134424-0920
Overflow valve opening pressure kPa   162 147 177
Overflow valve opening pressure kgf/cm2   1.65 1.5 1.8
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   4.8 4.77 4.83
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.75 60.25
Difference between angles 2
Cyl.1-2
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cal 1-3
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-5
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   A
Rack position   11.3
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   108.5 106.5 110.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Boost pressure kPa   37.3 37.3
Boost pressure mmHg   280 280
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.1+-0.5
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
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   800 800 800
Rack position   R1-0.7
Boost pressure kPa   10.7 10.7 12
Boost pressure mmHg   80 80 90
Boost compensator adjustment_02
Pump speed r/min   800 800 800
Rack position   R1(11.3)
Boost pressure kPa   24 24 24
Boost pressure mmHg   180 180 180
Timer adjustment
Pump speed r/min   1100--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1050
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1250
Advance angle deg.   1.5 1.2 1.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-2332
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)SMA RACK LIMIT; RAL (boost pressure exceeds P1 at N = N1) (4)Boost compensator stroke (5)Set idle sub-spring (6)Main spring setting (7)Perform governor adjustment at an ambient temperature of at least 15 deg C (rack limit spring is shape memory alloy).
----------
K=12 RAL=13.1+-0.1mm N1=350r/min P1=37.3kPa(280mmHg)
----------

Speed control lever angle

Test data 101603-2332
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(13deg)+-5deg b=(18deg)+-5deg

Stop lever angle

Test data 101603-2332
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)At delivery (3)Stopper bolt setting (4)Stopper bolt setting (5)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=33mm
----------
a=13deg+-5deg b=35deg+-5deg

Timing setting

Test data 101603-2332
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)




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