101603-9141 ZEXEL 9 400 619 554 BOSCH INJECTION-PUMP ASSEMBLY 9400619554 1016039141


 

Information injection-pump assembly

BOSCH 9 400 619 554 9400619554
ZEXEL 101603-9141 1016039141
101603-9141 INJECTION-PUMP ASSEMBLY
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Service parts 101603-9141 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3290
3. GOVERNOR 105490-5630
4. SUPPLY PUMP 105220-5200
5. AUTOM. ADVANCE MECHANIS 105643-0250
6. COUPLING PLATE 105661-0350
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5560
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3522
14. NOZZLE 105015-5150
15. NOZZLE SET

Include in #1:

101603-9141 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 554 9400619554
ZEXEL 101603-9141 1016039141


Zexel num
Bosch num
Firm num
Name
101603-9141 
9 400 619 554 
   
INJECTION-PUMP ASSEMBLY
K 14BE INJECTION PUMP ASSY 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 opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   3.3 3.25 3.35
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   10.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   60.8 58.6 63
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   9.1+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   10.5 8.5 12.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   65 65
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1000
Advance angle deg.   3.2 2.7 3.7
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   6.5 6 7
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-9141
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting (6)Rack difference between N = N2 and N = N3
----------
RT=1 TH=2.3mm SXL=11+0.2mm N1=450r/min N2=1500r/min N3=950r/min
----------

Speed control lever angle

Test data 101603-9141
F:Full speed
----------

----------
a=23deg+-5deg

0000000901

Test data 101603-9141
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=55mm
----------
a=5.5deg+-5deg b=20deg+-3deg

Stop lever angle

Test data 101603-9141
N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

Test data 101603-9141
(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)




Information:


Delco-Remy Alternator
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.Alternator (Bosch)
The alternator is driven by V-belts from the crankshaft pulley. This alternator is a three phrase, self-rectifying charging unit, and the regulator is part of the alternator.The 7N9720 Alternator has an output of 37A. The 9W3043 Alternator has an output of 40A.
Bosch Alternator
(1) Fan. (2) Stator winding. (3) Field winding. (4) Regulator. (5) Ball bearing. (6) Roller bearing. (7) Rotor. (8) Rectifier assembly.This alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes, and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.Alternator (Nippondenso)
The Nippondenso alternator has three-phase, full-wave rectified output. It is brushless. The rotor and bearings are the only moving parts. There is a 24 volt, 9G4574 Alternator with 35 amp output and a 12 volt, 8T9900 Alternator with a 55 amp output.
9G4574 Nippondenso Alternator
(1) Fan. (2) Front frame assembly. (3) Stator assembly. (4) Rotor assembly. (5) Field winding (coil assembly). (6) Regulator assembly. (7) Condenser (suppression capacitor). (8) Rectifier assembly. (9) Rear frame assembly.When the engine is started and the rotor turns inside the stator windings, three-phase alternating current (AC) and rapidly rising voltage is generated.A small amount of alternating current (AC) is changed (rectified) to pulsating direct current (DC) by the exciter diodes on the rectifier assembly. Output current from these diodes adds to the initial current which flows through the rotor field windings from residual magnetism. This will make the rotor a stronger magnet and cause the alternator to become activated automatically. As rotor speed, current and voltages increase, the rotor field current increases enough until the alternator becomes fully activated.The main battery charging current is charged (rectified) from AC to DC by the

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