101608-1660 ZEXEL 9 400 610 764 BOSCH INJECTION-PUMP ASSEMBLY 9400610764 1016081660

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 764 9400610764

ZEXEL 101608-1660 1016081660

Service parts 101608-1660 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8080

3. GOVERNOR 105412-2440

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5400

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4501

11. Nozzle and Holder ME078373

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

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-0920

15. NOZZLE SET

Include in #1:

101608-1660 as INJECTION-PUMP ASSEMBLY

107692-1622 as _

Cross reference number

BOSCH 9 400 610 764 9400610764

ZEXEL 101608-1660 1016081660

Zexel num

Bosch num

Firm num

Name

101608-1660
101608-1661

9 400 610 764

INJECTION-PUMP ASSEMBLY
6D16 * K 14BF PE6AD 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 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 4.2 4.15 4.25

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 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 57.5 56.5 58.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.1+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12 10.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 4 3.5 4.5

Remarks
Measure the actual speed, stop

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)Torque spring does not operate. (4)Set idle sub-spring (5)Main spring setting
----------
K=12
----------

Speed control lever angle

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

----------
a=7deg+-5deg b=20deg+-5deg

Stop lever angle

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

----------
a=26deg+-5deg b=53deg+-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)