Information injection-pump assembly
BOSCH
9 400 610 801
9400610801
ZEXEL
101696-9421
1016969421
NISSAN-DIESEL
16713Z6465
16713z6465

Rating:
Service parts 101696-9421 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5578
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 801
9400610801
ZEXEL
101696-9421
1016969421
NISSAN-DIESEL
16713Z6465
16713z6465
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
134424-1520
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
3.9
3.85
3.95
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
13.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
99.5
97.5
101.5
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
275
275
275
Average injection quantity
mm3/st.
8.6
6.8
10.4
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(13.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
99.5
98.5
100.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.05
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
103.5
100.3
106.7
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1+0.
3)
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
85.5
82.3
88.7
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.3
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
63
59.8
66.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
89
89
109
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-1.3
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1+0.
3)
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
450
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
(530)
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1120
Advance angle
deg.
0.5
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
4.5
4
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
(4)Boost compensator stroke: BCL
----------
T1=K20 BCL=1.3+-0.1mm
----------
----------
T1=K20 BCL=1.3+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=25deg+-5deg b=39deg+-3deg
----------
aa=36mm
----------
a=25deg+-5deg b=39deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)No return spring
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR

(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Ra.
(2)Install the shim (D) to the rod (C) and tighten nut (E).
(3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L.
(4)Release the rack fixing and mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack sensor adjustment (-0420)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set the speed to N1 r/min.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.02 V, then tighten the nut (F).
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(13.1)mm
----------
----------
L=33-0.2mm N1=700r/min Ra=R1(13.1)mm
----------
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:
Illustration 74 g02026337 Appendix D
Cleaned Filter Specification
Note: Scope: The following steps determine a properly cleaned Caterpillar filter.Note: This specification applies to filters that were cleaned of ash only. This specification is only valid subsequent to the "Recommended Cleaning Procedure". This specification should not be used to determine if soot filled filters are properly cleaned. All filters must be baked appropriately using the "Recommended Cleaning Procedure" prior to application of this specification.HEALTH AND SAFETY
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Adhere to all local Health and Safety rules and regulations. Use all the personal protective equipment listed below:
Respirator
Safety shoes
Safety glasses
Latex gloves
Lab coatRESOURCESNecessary equipment:
38 cm (15 inch) long by 0.9 mm (0.04 inch) thick stainless steel probe for "200 cpsi" (Cells/Square inch) filters
Tape measureMETHODEvaluation of a cleaned filter:Note: A filter MUST meet all criteria in this section below to be considered clean.
Inspect both inlet and outlet surfaces for oil/fuel contamination, gouges and/or cracks. No cracks may be visible. Gouges may not be exceed 4.0 mm (0.15 inch) deep.
There must be no filter movement within the filters banding. This movement is defined as the substrate moving past the bent-over flange. The filter must be even or below the bent-over flange.
There must not be any signs of the steel fiber ring coming loose or any mat material (cottony gauze) slipping past the filter. See Illustration 75 below.
The flanges are not damaged beyond repair.
There are no dents deeper than 6.4 mm (0.25 inch) in the outer can of the filter and the outer can is not cracked, torn or otherwise breached.
No more than 20 cells are allowed to be damaged (showing soot) on the outlet face of the filter. Refer to Illustrations 76 and 77.
Inspect the ash depth in the cells using the "Check Cell Depth" instructions below.
Illustration 75 g02026392
Proper placement of the filter within the banding
(1) Outside Can
(2) Bent-over flange
(3) Steel fiber ring
(4) Mat material
(5) FilterNote: Filter must be below the bent over-flange (2).
Illustration 76 g02026398
Acceptable filter with less than 20 damaged cells
Illustration 77 g02026399
Unacceptable filter with too many damaged cells
Check Cell Depth
Check cell depth by dropping the stainless steel probe into a cell location noted by a dot in Illustration 78 below.
Lightly tap the probe with a finger until the probe does not travel into the cell any further. Mark the probe to record the depth.
Illustration 78 g02026405
Measure the distance from the tip of the probe which entered the cell to the mark made on the probe. This distance is the cell depth. Repeat this step 17 times per Illustration 78.
If the probe travels a minimum of 28.6 cm (11.25 inch) in all cells, the filter is considered clean.
If the probe encounters heavy resistance in