Information injection-pump assembly
BOSCH
9 400 610 306
9400610306
ZEXEL
101696-9020
1016969020
Rating:
Service parts 101696-9020 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5570
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 306
9400610306
ZEXEL
101696-9020
1016969020
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
-
Rack position
12.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
83.7
82.1
85.3
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
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.5
7.7
11.3
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(12.5)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
83.7
82.7
84.7
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.55
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68.7
66.7
70.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
85
85
105
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
2
1.5
2.5
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=C35
----------
----------
T1=C35
----------
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=(37deg)+-3deg
----------
aa=100mm
----------
a=26.5deg+-5deg b=(37deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
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:
If the vehicle has a disconnect switch, the starting circuit can operate only after the disconnect switch is put in the ON position.The starting circuit is in operation only when the start switch is activated.The low amperage circuit and the charging circuit are both connected to the same side of the ammeter. The starting circuit connects to the opposite side of the ammeter.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.
Charging System Components
Alternator
Alternator Components (Typical Example)
(1) Brush holder. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end frame. (6) Fan assembly. (7) Slip rings. (8) Rectifier.The alternator has three phase, full-wave, rectified output. It is a brush type alternator.The alternator is an electrical and mechanical component driven by a belt from engine rotation. It is used to charge the storage battery during engine operation. The alternator is cooled by a fan that is a part of the alternator. The fan pulls air through holes in the back of the alternator. The air exits the front of the alternator, cooling it in the process.The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage. This process is done by rotating a direct current (DC) electromagnetic field (rotor) inside a three phase stator. The alternating current and voltage (generated by the stator) are changed to direct current by a three phase, full wave rectifier system using six silicone rectifier diodes. The alternator also has a diode trio which is an assembly made up of three exciter diodes. The diode trio rectifies field current needed to start the charging process. Direct current flows to the alternator output terminal.A solid state regulator is installed in the back of the alternator. Two brushes conduct current, through two slip rings, to the field coil on the rotor.There is also a capacitor mounted in the back of the alternator. The capacitor protects the rectifier from high voltages. It also suppresses radio noise.Regulator
The voltage regulator is a solid state (transistor, stationary parts) electronic switch which controls the alternator output. The regulator limits the alternator voltage to a preset value by controlling the field current. It feels the voltage in the system and switches "ON" and "OFF" many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output. Refer to Service Manual, SENR3862, for detailed service information for the Delco Remy 27 SI Series Alternator. For engines which have the alternator connected to an engine component, the ground strap must connect that component to the frame or to the battery ground.Starting System Components
Starter Solenoid
A solenoid is a magnetic switch that does two basic operations:1. Closes the high current starter motor circuit with a low current start switch circuit.2. Engages the starter motor pinion with the ring gear.
Typical SolenoidThe solenoid switch is made of an electromagnet (one or two sets of windings) around
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.
Charging System Components
Alternator
Alternator Components (Typical Example)
(1) Brush holder. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end frame. (6) Fan assembly. (7) Slip rings. (8) Rectifier.The alternator has three phase, full-wave, rectified output. It is a brush type alternator.The alternator is an electrical and mechanical component driven by a belt from engine rotation. It is used to charge the storage battery during engine operation. The alternator is cooled by a fan that is a part of the alternator. The fan pulls air through holes in the back of the alternator. The air exits the front of the alternator, cooling it in the process.The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage. This process is done by rotating a direct current (DC) electromagnetic field (rotor) inside a three phase stator. The alternating current and voltage (generated by the stator) are changed to direct current by a three phase, full wave rectifier system using six silicone rectifier diodes. The alternator also has a diode trio which is an assembly made up of three exciter diodes. The diode trio rectifies field current needed to start the charging process. Direct current flows to the alternator output terminal.A solid state regulator is installed in the back of the alternator. Two brushes conduct current, through two slip rings, to the field coil on the rotor.There is also a capacitor mounted in the back of the alternator. The capacitor protects the rectifier from high voltages. It also suppresses radio noise.Regulator
The voltage regulator is a solid state (transistor, stationary parts) electronic switch which controls the alternator output. The regulator limits the alternator voltage to a preset value by controlling the field current. It feels the voltage in the system and switches "ON" and "OFF" many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output. Refer to Service Manual, SENR3862, for detailed service information for the Delco Remy 27 SI Series Alternator. For engines which have the alternator connected to an engine component, the ground strap must connect that component to the frame or to the battery ground.Starting System Components
Starter Solenoid
A solenoid is a magnetic switch that does two basic operations:1. Closes the high current starter motor circuit with a low current start switch circuit.2. Engages the starter motor pinion with the ring gear.
Typical SolenoidThe solenoid switch is made of an electromagnet (one or two sets of windings) around