101608-6153 ZEXEL 9 400 612 420 BOSCH INJECTION-PUMP ASSEMBLY 9400612420 1016086153


101608-6153 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 420 9400612420
ZEXEL 101608-6153 1016086153

Service parts 101608-6153 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6640
3. GOVERNOR 105411-2071
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:

101608-6153 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 612 420 9400612420
ZEXEL 101608-6153 1016086153


Zexel num
Bosch num
Firm num
Name
101608-6153 
101608-6154 
9 400 612 420 
   
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 101608-6153
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
----------
K=8 BCL=1.2+-0.1mm
----------

Speed control lever angle

Test data 101608-6153
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(23deg)+-5deg b=(4deg)+-5deg

Stop lever angle

Test data 101608-6153
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)

Timing setting

Test data 101608-6153
(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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Group cross 101608-6153 ZEXEL

 
 
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101608-6153  

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