101603-9300 ZEXEL 9 400 619 685 BOSCH INJECTION-PUMP ASSEMBLY 9400619685 1016039300


101603-9300 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 685 9400619685
ZEXEL 101603-9300 1016039300

Service parts 101603-9300 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3510
3. GOVERNOR 105482-7231
4. SUPPLY PUMP 105220-5670
5. AUTOM. ADVANCE MECHANIS 105614-3400
6. COUPLING PLATE 105661-0401
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6690
11. Nozzle and Holder 16600Z5519
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4650
14. NOZZLE 105015-6380
15. NOZZLE SET

Include in #1:

101603-9300 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 685 9400619685
ZEXEL 101603-9300 1016039300


Zexel num
Bosch num
Firm num
Name
101603-9300 
101603-9301 
9 400 619 685 
   
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 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)
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   3.4 3.35 3.45
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   9.8
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   58.9 57.9 59.9
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   R1(10)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   80.6 79.6 81.6
Max. variation between cylinders %   0 -5 5
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   7.9+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   8.3 6.5 10.1
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 80
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-9300
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (5)Variable speed specification: idling adjustment (6)Main spring setting
----------
RT=1 TH=1.7mm SXL=R1+0.2mm DL=7-0.2mm
----------

Speed control lever angle

Test data 101603-9300
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(24deg)+-5deg b=(20deg)+-5deg

0000000901

Test data 101603-9300
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=19.5deg+-3deg

Stop lever angle

Test data 101603-9300
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg

Timing setting

Test data 101603-9300
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




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