101606-9461 ZEXEL 9 400 613 053 BOSCH INJECTION-PUMP ASSEMBLY 9400613053 1016069461


 

Information injection-pump assembly

BOSCH 9 400 613 053 9400613053
ZEXEL 101606-9461 1016069461
101606-9461 INJECTION-PUMP ASSEMBLY
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Service parts 101606-9461 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5290
3. GOVERNOR 105482-7401
4. SUPPLY PUMP 105210-5410
5. AUTOM. ADVANCE MECHANIS 105644-0530
6. COUPLING PLATE 105662-1400
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7550
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}
13. NOZZLE-HOLDER 105030-4530
14. NOZZLE 105015-9480
15. NOZZLE SET

Include in #1:

101606-9461 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 053 9400613053
ZEXEL 101606-9461 1016069461


Zexel num
Bosch num
Firm num
Name
101606-9461 
9 400 613 053 
  DPICO
INJECTION-PUMP ASSEMBLY
EM100 Q

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   131424-5720
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)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   4.3 4.25 4.35
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   7.7
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   96 94 98
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   (7.9)
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   105 99 111
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   E
Rack position   5.6+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   15 13 17
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   F
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   115 75 155
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   1130--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1080
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1330
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-9461
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: SXL (N = N1) (5)Damper spring setting
----------
RT=0.8 TH=1.5mm SXL=8.9+-0.1mm N1=400r/min
----------

Speed control lever angle

Test data 101606-9461
F:Full speed
----------

----------
a=(5.5deg)+-5deg

0000000901

Test data 101606-9461
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=23deg+-5deg b=35.5deg+-3deg

Stop lever angle

Test data 101606-9461
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Drive side
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg

Timing setting

Test data 101606-9461
(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=15deg
----------
a=(60deg)




Information:


Location of Screwdriver While Holding BellcrankK. Rotate the timing position sensor bellcrank clock wise by inserting the No. 2 Phillips screwdriver between the arm of the bellcrank in contact with the timing position sensor until the screwdriver can be inserted into the hole in the cover to hold the bellcrank in position.
Hold Timing Position Sensor Bellcrank In PositionL. Install the gasket and timing advance housing (4).M. Remove the screwdriver to allow the bellcrank to contact the power piston.9. Check the timing sensor position calibration as described in P-531: Timing Position Sensor/Calibration.10. Install the timing solenoid (BTM). Make sure the arm of the timing solenoid is in the center groove of the control spool collar.11. Install the timing advance position sensor cover (3).P-540: Idle Shutdown Timer
System Operation
The idle shutdown timer is a feature which helps improve fuel consumption by limiting idling time. The timer may be programmed to shut down the idling engine after a period of time. This "shutdown time" is a customer specified parameter, and may be programmed for any period from 3 to 60 minutes. Programming the time to zero disables the idle shutdown timer.The timer is activated when the parking brake is set, vehicle speed is zero, and the engine is not under load. Ninety seconds before the programmed time is reached, the diagnostic lamp will begin to flash rapidly. If the driver moves the clutch pedal or brake pedal during this 90 second period, the timer will be overridden and is reset. A diagnostic code 71-00 will be set when the driver overrides the timer using the clutch or brake.If the timer is activated and allowed to shutdown the engine, then a code 71-01 will be set. Code 71-01 merely records the event and does not indicate a fault in PEEC III. If any of the codes for vehicle speed are Active, the idle shutdown timer will not operate.Diagnostic Codes
Functional Test
P-541: Multi-Torque
System Operation
Multi-Torque is an optional feature available with certain PEEC III engines. The feature is available only in certain personality modules.The 310 Multi-Torque provides an otherwise standard 310 hp PEEC III engine with two different torque curves. In all gears except top gear, the engine performs as a standard 310 hp PEEC III. In top gear, however, the engine is provided with the torque of a standard 310 hp at 1800 rpm, but with the peak torque of 350 hp at 1150 rpm (see the following illustrations).PEEC III determines whether the vehicle is in top gear by sensing the ratio of engine speed to vehicle speed. If the ratio of engine speed/vehicle speed is less than 26.6, the engine will perform like a standard 310 hp PEEC III.The 350 Multi-Torque works just like the 310Multi-Torque, except for two key differences. First, the multi-torque curve provides the engine with the standard 350 hp torque at 1800 rpm, and with the peak torque of a 400 hp at 1200 rpm (see the following illustration). Second, the multi-torque is in effect in the top two gears,

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