101608-6351 ZEXEL 9 400 613 184 BOSCH INJECTION-PUMP ASSEMBLY 9400613184 1016086351

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 184 9400613184

ZEXEL 101608-6351 1016086351

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Service parts 101608-6351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6790

3. GOVERNOR 105964-0060

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105680-5091

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:

101608-6351 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-0443 as _

Cross reference number

BOSCH 9 400 613 184 9400613184

ZEXEL 101608-6351 1016086351

Zexel num

Bosch num

Firm num

Name

101608-6351
101608-6352

9 400 613 184

INJECTION-PUMP ASSEMBLY
* 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

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

Rack position (11.1)

PWM % 50.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 124.5 123.5 125.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Injection quantity adjustment_02

Rack position (7.3)

PWM % 29.4+-2. 8

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 11 9.5 12.5

Max. variation between cylinders % 0 -15 15

Governor adjustment

Pump speed r/min 600

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Start

Governor adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Governor adjustment_03

Pump speed r/min 850

Advance angle deg. 0.5

Load 4/4

Governor adjustment_04

Pump speed r/min 1025

Advance angle deg. 1.5 1 2

Load 4/4

Remarks
Finish

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=5deg+-5deg b=37deg+-5deg

0000000901

(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
----------
a=(0deg)

Stop lever angle

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------

Information:

Fan Belt
Removal
Fig. 1-Cap Screw and BoltLoosen cap screw and alternator mounting bolt (Fig. 1). Move alternator so fan belt can be moved off pulley. Remove fan belt.Repair
Inspect belts for:1 Cracking2 Rupture3 Tears4 Burning5 Gouging6 Wear7 Internal Cord Failure8 Cuts9 Peeling, Fraying, ChewingDo not reuse a damaged belt. Install a new belt.Installation
Fig. 2-Install Fan BeltPut fan belt over fan (1, Fig. 2). Put fan belt over crankshaft pulley (2) and alternator pulley (3). Position fan belt in pulley grooves.Adjust fan belt tension (Group 9010).Crankshaft Pulley
Removal
Remove fan belt from pulley (Group 0429).
Fig. 3-Cap Screw and WasherRemove cap screw and washer (Fig. 3) holding crankshaft pulley on crankshaft. IMPORTANT: On six cylinder engines the crankshaft pulley is also a vibration damper. Do not drop or hammer on vibration dampers.
Fig. 4-D01200AA PullerUsing D01200AA Puller (Fig. 4), pull crankshaft pulley off crankshaft.Repair
Inspect pulley sheaves for cracks and wear. Replace pulley if damaged.For vibration damper repair, see Group 0401.Installation
Position crankshaft pulley on crankshaft.Put washer on cap screw. Install cap screw through crankshaft pulley into crankshaft.
Fig. 5-Cap ScrewTighten cap screw (Fig. 5) to 85 lb-ft (115 N m) (12 kg-m).Install fan belts (Group 0429).Adjust fan belt tension (Group 9010).