101608-6220 ZEXEL 9 400 611 944 BOSCH INJECTION-PUMP ASSEMBLY 9400611944 1016086220


101608-6220 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 611 944 9400611944
ZEXEL 101608-6220 1016086220

Service parts 101608-6220 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8760
3. GOVERNOR 105411-2000
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105672-9010
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4190
11. Nozzle and Holder ME078067
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3350
14. NOZZLE 105025-0370
15. NOZZLE SET

Include in #1:

101608-6220 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 611 944 9400611944
ZEXEL 101608-6220 1016086220


Zexel num
Bosch num
Firm num
Name
101608-6220 
101608-6221 
9 400 611 944 
   
INJECTION-PUMP ASSEMBLY
6D16T * 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   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   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   10.6
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   106 105 107
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   44 44
Boost pressure mmHg   330 330
Injection quantity adjustment_02
Adjusting point   C
Rack position   8+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8 6.5 9.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R1-0.9
Boost pressure kPa   20 17.3 22.7
Boost pressure mmHg   150 130 170
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   R1(10.6)
Boost pressure kPa   30.7 24 37.4
Boost pressure mmHg   230 180 280
Timer adjustment
Pump speed r/min   1150--
Advance angle deg.   0 0 0
Load   4/4
Remarks
Beginning of advance.
 
Timer adjustment_02
Pump speed r/min   450
Advance angle deg.   2 1.5 2.5
Load   0/4
Remarks
Start
 
Timer adjustment_03
Pump speed r/min   (550)
Advance angle deg.   0 0 0
Load   0/4
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1100
Advance angle deg.   0.5
Load   4/4
Timer adjustment_05
Pump speed r/min   1400
Advance angle deg.   2.5 2 3
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-6220
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Main spring setting (4)Set idle sub-spring (5)Boost compensator stroke: BCL
----------
K=13 BCL=0.9+-0.1mm
----------

Speed control lever angle

Test data 101608-6220
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(29deg)+-5deg b=(18deg)+-5deg

Stop lever angle

Test data 101608-6220
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 101608-6220
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 101608-6220
(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=10deg
----------
a=(1deg)




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