101608-6482 ZEXEL 9 400 613 382 BOSCH INJECTION-PUMP ASSEMBLY 9400613382 1016086482


101608-6482 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 382 9400613382
ZEXEL 101608-6482 1016086482

Service parts 101608-6482 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6730
3. GOVERNOR 105411-2551
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105680-9050
6. COUPLING PLATE 105663-1150
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5340
11. Nozzle and Holder ME441452
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3660
14. NOZZLE 105025-4020
15. NOZZLE SET

Include in #1:

101608-6482 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 382 9400613382
ZEXEL 101608-6482 1016086482


Zexel num
Bosch num
Firm num
Name
101608-6482 
101608-6483 
9 400 613 382 
   
INJECTION-PUMP ASSEMBLY
* K 14BN 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   11.5
Pump speed r/min   895 895 895
Average injection quantity mm3/st.   122.5 121.5 123.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   48.7 48.7
Boost pressure mmHg   365 365
Injection quantity adjustment_02
Adjusting point   -
Rack position   8.5+-0.5
Pump speed r/min   350 350 350
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   12.4++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 120 130
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   R1-1.45
Boost pressure kPa   13.3 10.6 16
Boost pressure mmHg   100 80 120
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(11.5)
Boost pressure kPa   35.3 28.6 42
Boost pressure mmHg   265 215 315
Timer adjustment
Pump speed r/min   830--
Advance angle deg.   0 0 0
Load   4/4
Remarks
Beginning of advance.
 
Timer adjustment_02
Pump speed r/min   430
Advance angle deg.   3 2.5 3.5
Load   0/4
Remarks
Start
 
Timer adjustment_03
Pump speed r/min   (550)
Advance angle deg.   0 0 0
Load   0/4
Timer adjustment_04
Pump speed r/min   780
Advance angle deg.   0.5
Load   4/4
Timer adjustment_05
Pump speed r/min   895
Advance angle deg.   0.75 0.25 1.25
Load   4/4
Timer adjustment_06
Pump speed r/min   -
Advance angle deg.   1.5 1 2
Load   4/4
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101608-6482
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set at delivery (6)Set idle sub-spring
----------
K=5 BCL=1.45+-0.1mm
----------

Speed control lever angle

Test data 101608-6482
F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=905r/min bb=760r/min
----------
a=20deg+-5deg b=8deg+-5deg c=5deg+-5deg

Stop lever angle

Test data 101608-6482
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 101608-6482
(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=6deg
----------
a=(3deg)




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