101608-6260 ZEXEL 9 400 611 713 BOSCH INJECTION-PUMP ASSEMBLY 9400611713 1016086260

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 713 9400611713

ZEXEL 101608-6260 1016086260

Service parts 101608-6260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9250

3. GOVERNOR 105401-1230

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-1200

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6781

11. Nozzle and Holder ME219131

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

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1040

15. NOZZLE SET

Include in #1:

101608-6260 as INJECTION-PUMP ASSEMBLY

Include in #2:

104748-0072 as _

Cross reference number

BOSCH 9 400 611 713 9400611713

ZEXEL 101608-6260 1016086260

Zexel num

Bosch num

Firm num

Name

101608-6260
101608-6261

9 400 611 713

INJECTION-PUMP ASSEMBLY
6D34TL * K 14BE 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 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.5 3.45 3.55

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 8.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 91.5 90.5 92.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 64 64

Boost pressure mmHg 480 480

Injection quantity adjustment_02

Adjusting point -

Rack position 6.1+-0.5

Pump speed r/min 525 525 525

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

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.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55 55 60

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.4

Boost pressure kPa 38.7 33.4 44

Boost pressure mmHg 290 250 330

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(8.7)

Boost pressure kPa 50.7 50.7 50.7

Boost pressure mmHg 380 380 380

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 750+-25

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL (7)Rack difference between N = N1 and N = N2
----------
K=16 BCL=0.4+-0.1mm N1=1050r/min N2=230r/min
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14.5deg
----------
a=(130deg)