Information injection-pump assembly
BOSCH
9 400 619 433
9400619433
ZEXEL
106673-7004
1066737004
Rating:
Service parts 106673-7004 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME151161
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
106673-7004
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 433
9400619433
ZEXEL
106673-7004
1066737004
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
13.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
172.5
168.2
176.8
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
410
410
410
Each cylinder's injection qty
mm3/st.
26
22.1
29.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
172.5
171.5
173.5
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+0.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
161.5
157.5
165.5
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.85
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
172.5
166.5
178.5
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-1.6
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2[R1-1.
75]
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
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)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AE17 BCL=1.6+-0.1mm
----------
----------
T1=AE17 BCL=1.6+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=2deg+-5deg b=39.5deg+-3deg
----------
aa=37.5mm
----------
a=2deg+-5deg b=39.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.)
(2)Normal engine position (equivalent to R = cc).
(3)Use the hole above R = dd
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=54mm
----------
a=40deg+-5deg b=29.5deg+-5deg c=(20.5deg)
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=7.6+-0.1mm
----------
----------
N1=325r/min Ra=7.6+-0.1mm
----------
0000001601 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(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)
----------
N1=1100r/min Ra=R1(13.4)+0.9mm
----------
----------
N1=1100r/min Ra=R1(13.4)+0.9mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=5deg
----------
a=(2deg)
----------
aa=5deg
----------
a=(2deg)
Information:
1. Remove the bolt and lock that holds suction bell (1) to the oil pan plate. Remove two bolts (4) that hold the elbow to the oil pump.
Oil pump idler gear (2) can fall off the pump when the pump is removed. To prevent injury, always hold the gear on the pump when the pump is removed.
2. Remove the bolts and locks that hold the oil pump to the engine. Remove oil pump (3).3. Install idler gear (2) on oil pump (3). Put the oil pump in position on the engine as shown with idler gear (2) engaged with the crankshaft gear. Install the bolts and locks that hold the oil pump to the engine.4. Install bolts (4) that hold the elbow to the oil pump.5. Install the bolt and lock that hold suction bell (1) to the oil pan plate.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump (3304) or remove oil pump (3306) 1. Remove idler gear (2). Remove the bearing from the idler gear with Tool (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with Tool (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), the keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with Tool (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with Tool (A) and a press as follows:a. Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with Tool (A) and a press as follows:a. Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before
Oil pump idler gear (2) can fall off the pump when the pump is removed. To prevent injury, always hold the gear on the pump when the pump is removed.
2. Remove the bolts and locks that hold the oil pump to the engine. Remove oil pump (3).3. Install idler gear (2) on oil pump (3). Put the oil pump in position on the engine as shown with idler gear (2) engaged with the crankshaft gear. Install the bolts and locks that hold the oil pump to the engine.4. Install bolts (4) that hold the elbow to the oil pump.5. Install the bolt and lock that hold suction bell (1) to the oil pan plate.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump (3304) or remove oil pump (3306) 1. Remove idler gear (2). Remove the bearing from the idler gear with Tool (B).2. Remove suction bell (1).3. Remove the bolt and the washer from the oil pump drive gear. 4. Remove the drive gear from the shaft with Tool (A).5. Remove the key from the pump shaft.6. Remove bolts (3) from the pump body. 7. Remove body (8), two gears (7), the keys and spacer (4) from the pump.8. Remove two shafts (5) and the gears.9. Remove bolts (6), the cover and the pressure relief valve from the body. 10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with Tool (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with Tool (A) and a press as follows:a. Put bearings (1) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with Tool (A) and a press as follows:a. Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump body. Make sure the joints in the bearings are at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check the condition of the relief valve. Check the condition and specifications for all the parts of the oil pump before