Information injection-pump assembly
BOSCH
9 400 610 136
9400610136
ZEXEL
106871-0142
1068710142
NISSAN-DIESEL
1670097570
1670097570
Rating:
Service parts 106871-0142 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97019
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106871-0142
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 610 136
9400610136
ZEXEL
106871-0142
1068710142
NISSAN-DIESEL
1670097570
1670097570
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
3.65
3.6
3.7
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5
Cal 1-5 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5
Cal 1-3 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5
Cyl.1-2 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
107.2
106.2
108.2
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
11.3
9.3
13.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.4
0.9
1.9
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)After completing adjustment of the broken line, set the lever at the unbroken line position.
(2)Rack limit using the stop lever: R1
(3)Rack difference from N = N1
(4)Beginning of damper spring operation: DL
----------
R1=10.6+0.2mm N1=700r/min DL=5.7-0.2mm
----------
----------
R1=10.6+0.2mm N1=700r/min DL=5.7-0.2mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=16deg+-5deg b=20deg+-3deg
----------
----------
a=16deg+-5deg b=20deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=31deg+-5deg
----------
----------
a=12deg+-5deg b=31deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)-
(4)-
----------
----------
a=(90deg)
----------
----------
a=(90deg)
Information:
Installation of Nozzles, Ether Supply Tubes and Connectors
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of