Information injection-pump assembly
BOSCH
9 400 615 295
9400615295
ZEXEL
101603-9301
1016039301
NISSAN-DIESEL
16713Z6104
16713z6104
Rating:
Service parts 101603-9301 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5519
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 615 295
9400615295
ZEXEL
101603-9301
1016039301
NISSAN-DIESEL
16713Z6104
16713z6104
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
Overflow valve
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
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
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
58.9
57.9
59.9
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
R1(10)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
80.6
79.6
81.6
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.9+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.3
6.5
10.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
80
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel setting for starting: SXL (N = N1)
(3)Damper spring setting
(4)Variable speed specification: idling adjustment
(5)Main spring setting
----------
SXL=R1+0.2mm N1=500r/min
----------
----------
SXL=R1+0.2mm N1=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(24deg)+-5deg b=(20deg)+-5deg
----------
----------
a=(24deg)+-5deg b=(20deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=19.5deg+-3deg
----------
----------
a=18deg+-5deg b=19.5deg+-3deg
Stop lever angle
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
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engine. Service work can be done with it installed on engine.1. Remove air bleed lines (2). 2. Remove bolts (1), flange (3), the flange assembly and the gaskets.3. Remove the bolts and the cover. 4. Remove bolts (5), solenoid (4) and the gasket.5. Remove two bolts (7) and fuel ratio control (6).6. Remove the shutoff housing from the cover. 7. Remove the bolts, lever (10) and shaft (8).8. Remove the bolts, lever (9) and shaft (11).9. Remove seal (12) from the shutoff housing. Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be 1.0 mm (.039 in.) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Put shaft (5) in position in housing (4).3. Install lever (6) and the bolts. 4. Install shaft (2), lever (3) and the bolts. Make an alignment of the notch in shaft (2) with lever (3). 5. Put cover (7) in position on shutoff housing assembly (8) and install the bolts.6. Put fuel ratio control (10) in position and install the bolts. 7. Install the gasket, solenoid (9) and bolts on the cover.8. Put the cover in position and install the bolts.9. Install the gasket, flange assembly, gasket, flange (11) and the bolts.10. Connect air bleed lines (12).