Information injection-pump assembly
BOSCH
F 01G 09U 0HX
f01g09u0hx
ZEXEL
101607-9840
1016079840
NISSAN-DIESEL
16713Z6569
16713z6569
Rating:
Service parts 101607-9840 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5663
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/20.6{210}
14.
NOZZLE
Include in #1:
101607-9840
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-5410
as _
Cross reference number
BOSCH
F 01G 09U 0HX
f01g09u0hx
ZEXEL
101607-9840
1016079840
NISSAN-DIESEL
16713Z6569
16713z6569
Zexel num
Bosch num
Firm num
Name
F 01G 09U 0HX
16713Z6569 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FE6E * K 14BF PE6AD PE
FE6E * K 14BF PE6AD PE
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131425-0420
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
3.7
3.65
3.75
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
-
Rack position
11.7
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
92
90.4
93.6
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
Z
Rack position
9.5+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
9
7.2
10.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.7)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
92
91
93
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.95
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
97.5
93.5
101.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.35
)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
86.5
82.5
90.5
Fixing the lever
*
Injection quantity adjustment_06
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
(900)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1080
Advance angle
deg.
2
1.5
2.5
Timer adjustment_03
Pump speed
r/min
1225
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1425
Advance angle
deg.
6
5.5
6.5
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=L95
----------
----------
T1=L95
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=(46deg)+-3deg
----------
aa=100mm
----------
a=26.5deg+-5deg b=(46deg)+-3deg
Stop lever angle
N:Normal
S:Stop
(1)Use the hole at R = aa
(2)Without return spring
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-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:
Machine Preparation
Prepare the machine for maintenance.Refer to Operation and Maintenance Manual, SEBU8491, "Prepare the Machine for Maintenance".Removal Procedure
Illustration 2 g06215589
(A) 383-2040 Guard
(B) 8T-4195 Bolt
(C) 8T-4121 Hard Washer
(D) 384-0966 Insert
Remove and save the DEF guard (A), three bolts (B), three hard washers (C), and three inserts (D).
Illustration 3 g06217988
(C) 8T-4121 Hard Washer
(E) 368-4513 Side Plate
(F) 365-2227 Hose As
(G) 8T-4136 Bolt
(H) 1S-0994 Clip
(J) 8T-4137 Bolt
(K) 1S-1015 Clip
(L) 7K-1181 Cable Strap
Illustration 4 g06217851
(E) 368-4513 Side Plate
Illustration 5 g06219874
View of Area M
(C) 8T-4121 Hard Washer
(H) 1S-0994 Clip
(N) 399-3078 Machine Software Gp
(P) 434-1305 Insulation
(R) 326-4516 Cable Tie
(S) 8T-4195 Bolt
(T) 7X-7729 Washer
(U) 8T-4133 Nut
Remove six hard washers (C), two bolts (G), five clips (H), two bolts (J), clip (K), four cable straps (L), five cable ties (R), protective insulation (P), two bolts (S), two washers (T), and two nuts (U) from the hose assembly (F). Discard five clips (H), clip (K), five cable ties (R). Retain the rest of the parts.
Remove and discard hose assembly (F) from DEF tank and DEF Injector Mounting Gp (N). Refer to Illustration 3 and Illustration 5.Installation Procedure
Illustration 6 g06215872
(C) 8T-4121 Hard Washer
(G) 8T-4136 Bolt
(J) 8T-4137 Bolt
(1) 471-4171 Hose As
(2) 1S-0994 Clip
(3) 7K-1181 Cable Strap
(4) 1S-1015 Clip
Illustration 7 g06219875
View of Area M
(C) 8T-4121 Hard Washer
(N) 399-6078 DEF Injector & Mounting Gp
(P) 434-1305 Insulation
(S) 8T-4195 Bolt
(T) 7X-7729 Washer
(U) 8T-4133 Nut
(1) 471-4171 Hose As
(2) 1S-0994 Clip
(5) 326-4516 Cable Tie
Install new hose assembly (1) to the DEF tank and DEF injector mounting group (N). Secure hose assembly (1) using five clips (2), four cable straps (3), clip (4), six hard washers (C), two bolts (G), two bolts (J), two bolts (S), two washers (T), and two nuts (U) that were saved in Step 2 of Section "Removal Procedure". Refer to Illustration 6 and Illustration 7.
Secure protective insulation (P) that was saved in Step 2 of Section "Removal Procedure" to hose assembly (1) using five cable ties (5). Refer to Illustration 7.
Illustration 8 g06215593
(A) 383-2040 Guard
(V) Template
Illustration 9 g06215595
(X) 94.4 mm (3.72 inch)
(Y) 225 mm (8.9 inch)
Use Illustration 9 as a template and position the template onto guard (A), aligning to the edges. Trim the guard (A) according to the template. Refer to Illustration 8.Note: Lay the template flat on the guard. The trimmed area of the guard (A) is the curved area. The square cutout on the template is not to be cut, the square corner allows the template to lay flatter on the guard.
Illustration 10 g06215889
(A) 383-2040 Guard
(E) 368-4513 Side Plate
(1) 471-4171 Hose As
Install the modified DEF guard (A) using the hardware that was saved in Step 1 of Section "Removal Procedure".Note: Ensure adequate clearance has been obtained.
Return machine to service.
Prepare the machine for maintenance.Refer to Operation and Maintenance Manual, SEBU8491, "Prepare the Machine for Maintenance".Removal Procedure
Illustration 2 g06215589
(A) 383-2040 Guard
(B) 8T-4195 Bolt
(C) 8T-4121 Hard Washer
(D) 384-0966 Insert
Remove and save the DEF guard (A), three bolts (B), three hard washers (C), and three inserts (D).
Illustration 3 g06217988
(C) 8T-4121 Hard Washer
(E) 368-4513 Side Plate
(F) 365-2227 Hose As
(G) 8T-4136 Bolt
(H) 1S-0994 Clip
(J) 8T-4137 Bolt
(K) 1S-1015 Clip
(L) 7K-1181 Cable Strap
Illustration 4 g06217851
(E) 368-4513 Side Plate
Illustration 5 g06219874
View of Area M
(C) 8T-4121 Hard Washer
(H) 1S-0994 Clip
(N) 399-3078 Machine Software Gp
(P) 434-1305 Insulation
(R) 326-4516 Cable Tie
(S) 8T-4195 Bolt
(T) 7X-7729 Washer
(U) 8T-4133 Nut
Remove six hard washers (C), two bolts (G), five clips (H), two bolts (J), clip (K), four cable straps (L), five cable ties (R), protective insulation (P), two bolts (S), two washers (T), and two nuts (U) from the hose assembly (F). Discard five clips (H), clip (K), five cable ties (R). Retain the rest of the parts.
Remove and discard hose assembly (F) from DEF tank and DEF Injector Mounting Gp (N). Refer to Illustration 3 and Illustration 5.Installation Procedure
Illustration 6 g06215872
(C) 8T-4121 Hard Washer
(G) 8T-4136 Bolt
(J) 8T-4137 Bolt
(1) 471-4171 Hose As
(2) 1S-0994 Clip
(3) 7K-1181 Cable Strap
(4) 1S-1015 Clip
Illustration 7 g06219875
View of Area M
(C) 8T-4121 Hard Washer
(N) 399-6078 DEF Injector & Mounting Gp
(P) 434-1305 Insulation
(S) 8T-4195 Bolt
(T) 7X-7729 Washer
(U) 8T-4133 Nut
(1) 471-4171 Hose As
(2) 1S-0994 Clip
(5) 326-4516 Cable Tie
Install new hose assembly (1) to the DEF tank and DEF injector mounting group (N). Secure hose assembly (1) using five clips (2), four cable straps (3), clip (4), six hard washers (C), two bolts (G), two bolts (J), two bolts (S), two washers (T), and two nuts (U) that were saved in Step 2 of Section "Removal Procedure". Refer to Illustration 6 and Illustration 7.
Secure protective insulation (P) that was saved in Step 2 of Section "Removal Procedure" to hose assembly (1) using five cable ties (5). Refer to Illustration 7.
Illustration 8 g06215593
(A) 383-2040 Guard
(V) Template
Illustration 9 g06215595
(X) 94.4 mm (3.72 inch)
(Y) 225 mm (8.9 inch)
Use Illustration 9 as a template and position the template onto guard (A), aligning to the edges. Trim the guard (A) according to the template. Refer to Illustration 8.Note: Lay the template flat on the guard. The trimmed area of the guard (A) is the curved area. The square cutout on the template is not to be cut, the square corner allows the template to lay flatter on the guard.
Illustration 10 g06215889
(A) 383-2040 Guard
(E) 368-4513 Side Plate
(1) 471-4171 Hose As
Install the modified DEF guard (A) using the hardware that was saved in Step 1 of Section "Removal Procedure".Note: Ensure adequate clearance has been obtained.
Return machine to service.