101608-1450 ZEXEL 9 400 619 451 BOSCH INJECTION-PUMP ASSEMBLY 9400619451 1016081450

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 451 9400619451

ZEXEL 101608-1450 1016081450

Service parts 101608-1450 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8910

3. GOVERNOR 105411-1780

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105672-5380

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4460

11. Nozzle and Holder ME078365

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

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE 105025-0800

15. NOZZLE SET

Include in #1:

101606-0220 as _

101608-1450 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 451 9400619451

ZEXEL 101608-1450 1016081450

Zexel num

Bosch num

Firm num

Name

101608-1450
101608-1451

9 400 619 451

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 9.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 118.5 115 122

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_02

Adjusting point -

Rack position 6.4+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.6 9.1 12.1

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.

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-0.75

Boost pressure kPa 28 25.3 30.7

Boost pressure mmHg 210 190 230

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(9.4)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

Timer adjustment

Pump speed r/min 0

Advance angle deg. 2 1.5 2.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min 550

Advance angle deg. 0 0 0

Remarks
Finish

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 stroke: BCL (4)Rack difference between N = N1 and N = N2 (5)Main spring setting (6)Set idle sub-spring
----------
K=15 BCL=0.75+-0.1mm N1=750r/min N2=230r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Pump speed = aa (3)Pump speed = bb
----------
aa=755r/min bb=910r/min
----------
a=(1deg)+-5deg b=(20deg)+-5deg c=(6deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)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

(1)Pump vertical direction (2)Position of coupling's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(1deg)