101607-6861 ZEXEL 9 400 610 718 BOSCH INJECTION-PUMP ASSEMBLY 9400610718 1016076861

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 718 9400610718

ZEXEL 101607-6861 1016076861

Service parts 101607-6861 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8720

3. GOVERNOR 105492-7320

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105643-0990

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4130

11. Nozzle and Holder ME078066

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE

105015-8480

15. NOZZLE SET

Include in #1:

101402-7911 as _

101607-6861 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 718 9400610718

ZEXEL 101607-6861 1016076861

Zexel num

Bosch num

Firm num

Name

101607-6861
101607-6862

9 400 610 718

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 131424-5520

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 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 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 10.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 82 81 83

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 100 96 104

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 11.5 10 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

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 (5)Damper spring setting
----------
RT=1 TH=2.8mm
----------

Speed control lever angle

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

----------
a=(18deg)+-5deg b=(6deg)+-5deg

0000000901

F:Full load (1)Fix the lever at the full load position
----------

----------
a=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set stopper bolt so that rack position = aa (after adjusting, apply red paint). (2)Drive side
----------
aa=5.9-0.5mm
----------
a=57deg+-5deg b=52deg+7deg-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(0deg)