101608-6430 ZEXEL 9 400 613 005 BOSCH INJECTION-PUMP ASSEMBLY 9400613005 1016086430


101608-6430 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 005 9400613005
ZEXEL 101608-6430 1016086430

Service parts 101608-6430 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6790
3. GOVERNOR 105964-0060
4. SUPPLY PUMP 105210-5450
5. AUTOM. ADVANCE MECHANIS 105680-9040
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:

101608-6430 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 005 9400613005
ZEXEL 101608-6430 1016086430


Zexel num
Bosch num
Firm num
Name
101608-6430 
101608-6431 
9 400 613 005 
   
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   700
Advance angle deg.   0.5
Load   0/4
Governor adjustment_03
Pump speed r/min   (850)
Advance angle deg.   0 0 0
Load   4/4
Remarks
Measure the actual speed.
 
Governor adjustment_04
Pump speed r/min   1075
Advance angle deg.   1.5 1 2
Load   4/4
Remarks
Finish
 

Test data Ex:

Speed control lever angle

Test data 101608-6430
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

Test data 101608-6430
(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=(4deg)

Stop lever angle

Test data 101608-6430
(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%
----------




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