101605-9452 ZEXEL 9 400 610 702 BOSCH INJECTION-PUMP ASSEMBLY 9400610702 1016059452

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 702 9400610702

ZEXEL 101605-9452 1016059452

Service parts 101605-9452 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5420

3. GOVERNOR 105401-0892

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-1130

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6740

11. Nozzle and Holder 16600-Z5607

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE 105015-9170

15. NOZZLE SET

Include in #1:

101401-4880 as _

101605-9452 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 702 9400610702

ZEXEL 101605-9452 1016059452

Zexel num

Bosch num

Firm num

Name

101605-9452
101605-9453

9 400 610 702

INJECTION-PUMP ASSEMBLY
* K

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 131424-1520

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 91.5 89.5 93.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_02

Adjusting point B

Rack position R1(9.9)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 72 71 73

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point C

Rack position 6.9+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1(9.9)

Boost pressure kPa 4 4 8

Boost pressure mmHg 30 30 60

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position (10)

Boost pressure kPa 12.7 12.7 12.7

Boost pressure mmHg 95 95 95

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator excessive fuel lever at operation (at 0 boost pressure): L1 (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting (7)Rack difference between N = N1 and N = N2
----------
K=10 L1=11.9+-0.1mm BCL=(0.1)mm N1=1100r/min N2=800r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(15deg)+-5deg b=(23deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (at 0 boost)
----------
aa=11.9+-0.1mm
----------
a=(15deg) b=(25deg)

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)