Information injection-pump assembly
BOSCH
9 400 614 623
9400614623
ZEXEL
101601-5670
1016015670
HINO
220006440A
220006440a

Rating:
Service parts 101601-5670 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2133
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 623
9400614623
ZEXEL
101601-5670
1016015670
HINO
220006440A
220006440a
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
105780-8210
Nozzle
105780-0070
Bosch type code
DN12SD12T-1
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
Overflow valve
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.6
76
79.2
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
16.9
15.9
17.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.6
76.6
78.6
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
88.9
84.9
92.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
64.2
60.2
68.2
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.5
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
87.4
83.4
91.4
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
925--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
875
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
(920--)
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_04
Pump speed
r/min
1175+50
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_05
Pump speed
r/min
1400+50
Advance angle
deg.
5.5
5.2
5.8
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=F80
----------
----------
T1=F80
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=37deg+-3deg b=40deg+-5deg
----------
aa=55mm
----------
a=37deg+-3deg b=40deg+-5deg
Stop lever angle

N:Engine normal (pump normal)
S:Engine stop
(1)Use the hole at R = aa
(2)Set the stopper screw. (After setting, apply red paint.)
----------
aa=35mm
----------
a=14.5deg+-5deg b=(31deg)+-5deg
----------
aa=35mm
----------
a=14.5deg+-5deg b=(31deg)+-5deg
0000001501 LEVER

(N) Engine normal (pump normal)
(S) Engine stop
(A) stopper screw
(B) Stop direction (perpendicular)
Stop lever adjusting procedure
(1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above.
(2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra.
(3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc)
(4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc.
(5)After adjustment, apply red paint.
----------
Na=1530r/min Ra=5.9mm Rb=1.5mm Nb=1.5 Rc=- Nc=250r/min
----------
ra=37mm a=14.5deg+-5deg b=(31deg)+-5deg
----------
Na=1530r/min Ra=5.9mm Rb=1.5mm Nb=1.5 Rc=- Nc=250r/min
----------
ra=37mm a=14.5deg+-5deg b=(31deg)+-5deg
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Improper jumper cable connections can cause an explosion resulting in personal injury. Do not allow jump cable ends to contact each other or the engine.Prevent sparks near the batteries. They could cause vapors to explode. Do not smoke when observing battery electrolyte levels.Electrolyte is an acid and can cause personal injury if it contacts skin or eyes. Always wear eye protection when starting an engine with jump cables.
Use only equal voltage for jump starting. The use of a welder or higher voltage will damage the electrical system. Jump only using a battery source with the same voltage as the stalled engine.
Turn off all lights and accessories on the stalled vessel. Otherwise, they will operate when the jump source is connected. Before attaching the jumper cables, move START switch to the OFF position.Always connect the battery positive (+) to battery positive (+) and the battery negative (-) to battery negative (-). When using jumper cables, be sure to connect in parallel: POSITIVE (+) cable to POSITIVE (+) terminal of battery which is connected to starting motor solenoid and NEGATIVE (-) cable from external source to starting motor NEGATIVE (-) terminal. If not equipped with a starting motor NEGATIVE terminal, connect to the engine block.Do not allow the free ends of jumper cables to touch the engine. This helps avoid sparks. Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove first. Many batteries thought to be unusable, are still rechargeable. Refer to Special Instruction, SEHS7633, Battery Test Procedure, available from your Caterpillar dealer, for complete testing and charging information.When boost starting, refer to the instructions that follow to properly start the engine.1. Connect one end of cable to the POSITIVE (+) (ungrounded) terminal of the battery on the engine being started. Connect the other end to the POSITIVE (+) terminal of the power source.2. Connect one end of the second cable to the NEGATIVE (-) terminal of the power source. Connect the other end to the starting motor ground NEGATIVE (-) terminal or to the engine block. This prevents potential sparks from igniting combustible gases produced by some batteries.3. Begin cranking engine to start the engine and achieve idle speed after making sure the marine transmission is in NEUTRAL. Start the engine using the starting procedure described previously.4. After the engine starts, disconnect the cable from the starting motor ground NEGATIVE (-) terminal or engine block first. Disconnect the other end from the NEGATIVE (-) terminal of the power source. Disconnect the cable from the POSITIVE (+) terminal of the battery on the engine being started. Disconnect the other end of cable from the POSITIVE (+) terminal of the power source.To prevent electrical discharge damage, check to make sure the engine's electrical system has an engine-to-battery ground connection. For engines which have the alternator connected to an engine component, a ground strap must connect that component to the battery.If the engine is not electrically connected directly to the rails through mounting bolts,