101608-6451 ZEXEL 9 400 613 262 BOSCH INJECTION-PUMP ASSEMBLY 9400613262 1016086451


101608-6451 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 262 9400613262
ZEXEL 101608-6451 1016086451

Service parts 101608-6451 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6830
3. GOVERNOR 105411-2491
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105680-9010
6. COUPLING PLATE 105663-1150
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5190
11. Nozzle and Holder ME440071
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-3660
14. NOZZLE 105025-3250
15. NOZZLE SET

Include in #1:

101608-6451 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 262 9400613262
ZEXEL 101608-6451 1016086451


Zexel num
Bosch num
Firm num
Name
101608-6451 
101608-6452 
9 400 613 262 
   
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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
Rack position
After adjusting injection quantity.
  R=A
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   11
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   115 114 116
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   65.3 65.3
Boost pressure mmHg   490 490
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.7+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   16.5 15 18
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.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   11.2++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   100 100 110
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   375 375 375
Rack position   9.1
Boost pressure kPa   18.7 12 25.4
Boost pressure mmHg   140 90 190
Boost compensator adjustment_02
Pump speed r/min   375 375 375
Rack position   10.5
Boost pressure kPa   56 53.3 58.7
Boost pressure mmHg   420 400 440
Timer adjustment
Pump speed r/min   (600)
Advance angle deg.   3 2.5 3.5
Load   0/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   720
Advance angle deg.   0.5
Load   0/4
Timer adjustment_03
Pump speed r/min   (820)
Advance angle deg.   0 0 0
Load   4/4
Timer adjustment_04
Pump speed r/min   (1000)
Advance angle deg.   1.5 1 2
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-6451
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Rack difference between N = N1 and N = N2 (6)Set idle sub-spring
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K=7 BCL=1.4+-0.1mm N1=1050r/min N2=375r/min
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Speed control lever angle

Test data 101608-6451
F:Full speed I:Idle S:Stop
----------

----------
a=16deg+-5deg b=2deg+-5deg c=31deg+-3deg

Stop lever angle

Test data 101608-6451
N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101608-6451
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)
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0000001601 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------

----------

Timing setting

Test data 101608-6451
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
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a=(0deg)




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Group cross 101608-6451 ZEXEL

9 400 619 513 
 
INJECTION-PUMP ASSEMBLY
101608-6451  

101608-6452 
9 400 613 262 
 
INJECTION-PUMP ASSEMBLY
9 400 613 295 
 
INJECTION-PUMP ASSEMBLY
9 400 613 380 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

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