Information injection-pump assembly
BOSCH
9 400 612 697
9400612697
ZEXEL
101609-9180
1016099180
Rating:
Service parts 101609-9180 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101609-9180
as INJECTION-PUMP ASSEMBLY
Include in #2:
104232-6000
as _
Cross reference number
BOSCH
9 400 612 697
9400612697
ZEXEL
101609-9180
1016099180
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
131424-5720
Overflow valve opening pressure
kPa
255
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
94
93
95
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
12
10.7
13.3
Max. variation between cylinders
%
0
-14
14
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.
Injection quantity adjustment_03
Adjusting point
E
Rack position
9.6++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Rack difference between N = N1 and N = N2
(5)Set idle sub-spring
----------
K=10 N1=900r/min N2=400r/min
----------
----------
K=10 N1=900r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Stopper bolt setting
----------
----------
a=31deg+-3deg b=14deg+-5deg c=3deg+-5deg
----------
----------
a=31deg+-3deg b=14deg+-5deg c=3deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb.
(2)Normal
----------
aa=1-0.5mm bb=0r/min
----------
a=21deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Before any service work is to be 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 engines. Service work can be done with it installed on engine. 1. Remove the flange (1) and flange assembly (2) from the cover (3).2. Remove the cover from the pump housing by removing seven bolts. 3. Remove the solenoid (4) from the cover.4. Remove cover (6).5. Remove two bolts (5) that hold the cover to the shutoff housing. 6. Remove the cover from the shutoff housing (7). 7. Remove the lever (10) from the shaft (11).8. Remove the shaft (9) from the shutoff housing.9. Remove the lever (8) from the shaft (11).10. Remove the shaft (11) from the shutoff housing.11. Remove the 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 .039 in. (1.0 mm) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Install the shaft (3) in the shutoff housing.3. Install the lever (5) on the shaft (3).4. Install shaft (2) in the shutoff housing.5. Install the lever (4) on shaft (3). 6. Put the cover (6) in position on the shutoff housing and install two bolts that hold the cover to the housing. 7. Install the cover (8).8. Install the solenoid (7) on the cover.9. Install the cover (6) on the pump housing.10. Install the flange assembly and the flange on the cover.