101608-6520 ZEXEL 9 400 613 384 BOSCH INJECTION-PUMP ASSEMBLY 9400613384 1016086520


101608-6520 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 384 9400613384
ZEXEL 101608-6520 1016086520

Service parts 101608-6520 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-9290
3. GOVERNOR 105401-1410
4. SUPPLY PUMP 105220-5150
5. AUTOM. ADVANCE MECHANIS 105676-1320
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6920
11. Nozzle and Holder ME440837
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105048-3590
14. NOZZLE 105017-3120
15. NOZZLE SET

Include in #1:

101608-6520 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 384 9400613384
ZEXEL 101608-6520 1016086520


Zexel num
Bosch num
Firm num
Name
101608-6520 
101608-6521 
9 400 613 384 
   
INJECTION-PUMP ASSEMBLY
* K 14BE PE6A 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)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.2 3.15 3.25
Beginning of injection position
Drive 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   8.7
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   94.5 93.5 95.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
Injection quantity adjustment_02
Adjusting point   -
Rack position   6+-0.5
Pump speed r/min   515 515 515
Average injection quantity mm3/st.   8 6.7 9.3
Max. variation between cylinders %   0 -14 14
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   8.9++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   65 65 70
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   900 900 900
Rack position   R1-1
Boost pressure kPa   32 25.3 38.7
Boost pressure mmHg   240 190 290
Boost compensator adjustment_02
Pump speed r/min   900 900 900
Rack position   R1(8.7)
Boost pressure kPa   81.3 78.6 84
Boost pressure mmHg   610 590 630
Timer adjustment
Pump speed r/min   0
Advance angle deg.   3 2 3
Load   0/4
Timer adjustment_02
Pump speed r/min   650+-25
Advance angle deg.   3 2 3
Load   0/4
Remarks
Start
 
Timer adjustment_03
Pump speed r/min   750+-25
Advance angle deg.   0 0 0
Load   0/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-6520
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=14 BCL=1+-0.1mm
----------

Speed control lever angle

Test data 101608-6520
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=6.5deg+-5deg b=19deg+-5deg

Stop lever angle

Test data 101608-6520
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 101608-6520
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(130deg)




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