101603-2670 ZEXEL 9 400 613 102 BOSCH INJECTION-PUMP ASSEMBLY 9400613102 1016032670


101603-2670 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 102 9400613102
ZEXEL 101603-2670 1016032670

Service parts 101603-2670 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5430
3. GOVERNOR 105401-1130
4. SUPPLY PUMP 105210-4351
5. AUTOM. ADVANCE MECHANIS 105672-0790
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:

101603-2670 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 102 9400613102
ZEXEL 101603-2670 1016032670


Zexel num
Bosch num
Firm num
Name
101603-2670 
101603-2671 
9 400 613 102 
   
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   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   10.8
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   142.5 141 144
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   C
Rack position   5.9+-0.5
Pump speed r/min   435 435 435
Average injection quantity mm3/st.   8.5 7.5 9.5
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_03
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   135 135 145
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R1-1.4
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R1(10.8)
Boost pressure kPa   24 17.3 30.7
Boost pressure mmHg   180 130 230
Timer adjustment
Pump speed r/min   900--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   850
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   950
Advance angle deg.   0.7 0.4 1
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-2670
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Main spring setting (5)Set idle sub-spring (6)Boost compensator stroke
----------
K=13
----------

Speed control lever angle

Test data 101603-2670
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(5deg)+-5deg b=(17deg)+-5deg

Stop lever angle

Test data 101603-2670
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)

Timing setting

Test data 101603-2670
(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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