Information injection-pump assembly
BOSCH
9 400 619 679
9400619679
ZEXEL
101441-9710
1014419710
NISSAN-DIESEL
1671290162
1671290162
Rating:
Service parts 101441-9710 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660043G03
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 679
9400619679
ZEXEL
101441-9710
1014419710
NISSAN-DIESEL
1671290162
1671290162
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.15
2.1
2.2
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.7
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
51
50
52
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8
6.9
9.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_02
Pump speed
r/min
900
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
4.7
4.7
4.7
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Main spring setting
(4)Set idle sub-spring
(5)Rack difference between N = N1 and N = N2
----------
K=7 RAL=14.2+-0.1mm N1=750r/min N2=400r/min
----------
----------
K=7 RAL=14.2+-0.1mm N1=750r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Set the pump speed at aa
(3)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=0deg+-5deg b=24deg+-5deg c=6deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=0deg+-5deg b=24deg+-5deg c=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=53deg+-5deg
----------
----------
a=12deg+-5deg b=53deg+-5deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)-
----------
----------
a1=A a2=B r1=750r/min r2=750r/min Q1=51+-1mm3/st Q2=- c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
----------
----------
a1=A a2=B r1=750r/min r2=750r/min Q1=51+-1mm3/st Q2=- c1=+-2.5% c2=+-2.5% a3=18 a4=15 r3=900r/min r4=750r/min
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(100deg)
----------
aa=16deg
----------
a=(100deg)
Information:
Test Procedure
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The battery is a replaceable lithium battery. The battery provides backup power for approximately two years. The "BATT" LED on the front of the processor alerts you when the battery voltage has fallen below a threshold level.The red "FLT" LED is flashing during operation. The processor detects a major fault. The fault is in the processor expansion chassis or the fault is in the memory.The red "BATT" LED is illuminated. The battery voltage has fallen below a threshold level.The red "BATT" LED is not illuminated. The battery is functional.
Illustration 1 g00563546
Diagram of the LED indicators
Illustration 2 g00563548
Functional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Verify that the battery is connected.
Verify that the battery is properly connected.The results of the preceding procedure are in the following list:
The battery is properly connected. Replace the battery. Verify that the repair resolves the problem. Refer to Maintenance Procedure, "Battery - Replace". Stop.
The battery is not properly connected. Proceed to 3.
Replace the battery.
To avoid damage to electronic components, do not remove the processor from the SLC 5/04 Chassis until all power is removed from the power supply.Do not expose memory modules to surfaces or areas that may typically hold an electrostatic charge.
Secure power to the processor.
Press the retaining clips at the top of the processor and press the retaining clips at the bottom of the processor.
Remove the processor from the chassis.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the battery. Remove the battery.
Install the new battery. Connect the new battery.
Align the processor and the guides in the chassis.
Gently slide the processor in the chassis. Secure the top retainer clips and secure the bottom retainer clips.
Install a wire tie in order to secure the wiring.The results of the preceding procedure are in the following
System Operation
The SLC 5/04 diagnostic indicators are located on the front of the following components: Power Supply, CPU and I/O Modules.The diagnostic indicators help trace the source of the fault. Faults can be found in the following components: Input devices, Output devices, Wiring and The controller.The battery is a replaceable lithium battery. The battery provides backup power for approximately two years. The "BATT" LED on the front of the processor alerts you when the battery voltage has fallen below a threshold level.The red "FLT" LED is flashing during operation. The processor detects a major fault. The fault is in the processor expansion chassis or the fault is in the memory.The red "BATT" LED is illuminated. The battery voltage has fallen below a threshold level.The red "BATT" LED is not illuminated. The battery is functional.
Illustration 1 g00563546
Diagram of the LED indicators
Illustration 2 g00563548
Functional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Verify that the battery is connected.
Verify that the battery is properly connected.The results of the preceding procedure are in the following list:
The battery is properly connected. Replace the battery. Verify that the repair resolves the problem. Refer to Maintenance Procedure, "Battery - Replace". Stop.
The battery is not properly connected. Proceed to 3.
Replace the battery.
To avoid damage to electronic components, do not remove the processor from the SLC 5/04 Chassis until all power is removed from the power supply.Do not expose memory modules to surfaces or areas that may typically hold an electrostatic charge.
Secure power to the processor.
Press the retaining clips at the top of the processor and press the retaining clips at the bottom of the processor.
Remove the processor from the chassis.
To avoid potential damage to the processor, handle all modules by the ends of the carrier or edges of the plastic housing. Skin oil or dirt can corrode metallic surfaces, inhibiting electrical contact.
Disconnect the battery. Remove the battery.
Install the new battery. Connect the new battery.
Align the processor and the guides in the chassis.
Gently slide the processor in the chassis. Secure the top retainer clips and secure the bottom retainer clips.
Install a wire tie in order to secure the wiring.The results of the preceding procedure are in the following