101607-1580 ZEXEL 9 400 619 603 BOSCH INJECTION-PUMP ASSEMBLY 9400619603 1016071580


101607-1580 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 603 9400619603
ZEXEL 101607-1580 1016071580

Service parts 101607-1580 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9690
3. GOVERNOR 105931-8410
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0540
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6780
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3900
14. NOZZLE 105015-6440
15. NOZZLE SET

Include in #1:

101607-1580 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 619 603 9400619603
ZEXEL 101607-1580 1016071580


Zexel num
Bosch num
Firm num
Name
101607-1580 
101607-1581 
9 400 619 603 
   
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   131424-5520
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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   3.3 3.25 3.35
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   -
Rack position   11.1
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   63.7 61.8 65.6
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   8.7+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   10.2 8.7 11.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.1)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   63.7 62.7 64.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   C
Rack position   R1+0.2
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   41.7 37.7 45.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   73 63 83
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_06
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   10 8.5 11.5
Fixing the rack   *
Remarks
(check)
 
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.   0.5
Timer adjustment_03
Pump speed r/min   1200
Advance angle deg.   2.7 2.2 3.2
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-1580
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=F47
----------

Speed control lever angle

Test data 101607-1580
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101607-1580
N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb and confirm non-injection. (Rack position = cc is non-injection rack position.) (2)After setting the stopper bolt, confirm non-injection at speed dd. (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1400r/min bb=6.7-0.5mm cc=(8.3)mm dd=275r/min ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

0000001601 LEVER

Test data 101607-1580
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=41deg+-3deg c=18.5deg+-5deg

Timing setting

Test data 101607-1580
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(0deg)




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