101608-6203 ZEXEL 9 400 613 054 BOSCH INJECTION-PUMP ASSEMBLY 9400613054 1016086203


101608-6203 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 054 9400613054
ZEXEL 101608-6203 1016086203

Service parts 101608-6203 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6640
3. GOVERNOR 105411-2081
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105672-5570
6. COUPLING PLATE 105663-1090
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4860
11. Nozzle and Holder ME440071
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3660
14. NOZZLE 105025-1900
15. NOZZLE SET

Include in #1:

101608-6203 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 054 9400613054
ZEXEL 101608-6203 1016086203


Zexel num
Bosch num
Firm num
Name
101608-6203 
101608-6204 
9 400 613 054 
   
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   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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   11.9
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   143.5 142.5 144.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.8+-0.5
Pump speed r/min   425 425 425
Average injection quantity mm3/st.   16.5 15 18
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.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   12.1++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   130 130 140
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R1-1.2
Boost pressure kPa   18.7 12 25.4
Boost pressure mmHg   140 90 190
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(11.15 )
Boost pressure kPa   57.3 54.6 60
Boost pressure mmHg   430 410 450
Timer adjustment
Pump speed r/min   1100++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1100.
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   4 4 4
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101608-6203
N:Pump speed R:Rack position (mm) (1)Target notch: 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: BCL (7)At delivery
----------
K=8 BCL=1.2+-0.1mm
----------

Speed control lever angle

Test data 101608-6203
F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)Speed = bb (set position for delivery) (3)Stopper bolt setting (4)Actual measurement
----------
aa=1270r/min bb=1325r/min
----------
a=(23deg)+-5deg b=(4deg)+-5deg c=31deg+-3deg

Stop lever angle

Test data 101608-6203
N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101608-6203
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(0.3~0.45kgf-m)
----------

Timing setting

Test data 101608-6203
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(7deg)




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