Dismantling And Installing The Fuel-Injection Pump (As from 3 cylinder engine)
It is assumed that the vee-belt tensioner or cover is dismantled.
Dismantling:
1. Disconnect the fuel line attached to the solenoid valve. Disconnect the flexible tubing delivering fuel to the feed pump and injection pump. Dismantle the fuel line connecting the fuel filter with the injection pump. Disconnect the leak-off line and the fuel delivery lines attached to the injection pump.
7-9
NOTE: Immediately the pipes are disconnected, plug the bores and fit caps over the connecting stubs of the fuel system.
Fig. 7-9
7-10
2. Unscrew the nuts securing the injection pump drive to the injection pump shaft. (For slotted nut use double spanner No. 110330).
Fig. 7-10
3. Remove the spring lockwasher. Make sure that it does not drop into the crankcase.
Important:
As from 1975, the hub was modified in the case of rigid drive.
(The thread for attachment of universal device No. 110340 with sleeve has been omitted).
See: DISMANTLING AND INSTALLING INJECTION PUMP WITH MODIFIED HUB FOR RIGID DRIVE (as from 3-cylinder engine)
4. Remove gearwheel fastening screws.
7-11
5. If the engine has an injection timer mount the tool without sleeve on the injection pump drive. If the engine has no injection timer, mount the tool with sleeve on the injection pump drive. (Universal device No. 110340).
Fig. 7-11
7-12
6. Pull the injection pump drive from the injection pump shaft.
Fig. 7-12 left and right
NOTE: Do not rotate the crankshaft.
7. Unscrew the nuts on the injection pump and remove the injection pump. Remove the rubber O-seal on the injection pump. If necessary, dismantle the cut-out system attached to the injection pump.
Installing:
7-13
1. Re-install the automatic stop system removed from the injection pump.
Fig. 7-13
2. Check whether the Woodruff key is fitted to the injection pump shaft. If it is not, install one.
7-14
3. Assemble a new rubber O-seal to the injection pump.
Fig. 7-14
7-15
4. Install the injection pump so that the Woodruff key in the injection pump shaft engages in the groove of the injection pump drive and the connections for the fuel delivery lines face diagonally upwards.
Fig. 7-15
7-16
5. Line up the notches in the injection pump and intermediate flange. Assemble the nuts.
Fig. 7-16
7-17
6. Screw the nuts on the fuel-injection pump drive. (Use a 19 mm socket spanner or double spanner No. 110330).
Fig. 7-17
Attention:
Slotted nut replaced as from 1977 by clamping nut 13a/fl. For tightening instructions, see Technical Data.
7-18
7. Assemble and tighten the union of the injection delivery line, so that the latter is free from tension.
Fig. 7-18
7-19
8. Connect the leak-off line and the line connecting with the solenoid valve, and at the same time fit a new gasket.
Fig. 7-19
9. Assemble new gaskets and connect the fuel pipes or flexible tubing leading from the fuel feed pump to the delivery filter and from this filter to the injection pump.
7-20
10. If the engine is equipped with an automatic cut-out, install the return spring thereof.
Fig. 7-20
11. Adjust the fuel-injection point in accordance with the instructions given in this manual. (See Section 2).
Dismantling And Installing Injection Pump With Modified Hub For Rigid Drive (as from 3-cylinder engine)
It is assumed that the V-belt tensioner or cover is dismantled.
Dismantling:
1. Disconnect fuel line attached to solenoid valve. Disconnect flexible tubing delivering fuel to feed pump and injection pump. Dismantle fuel line connecting filter with injection pump. Disconnect leak-off line and fuel delivery lines attached to injection pump.
7-21
NOTE: Close immediately bores and connections of fuel system.
Fig. 7-21
7-22
2. Loosen and remove screws securing gear.
Fig. 7-22
7-23
3. Unscrew nuts securing injection pump and remove injection pump.
Fig. 7-23
NOTE: Do not rotate crankshaft anymore.
7-24
4. Pull hub off injection pump.
Fig. 7-24
Installation:
7-25
1. Check whether Woodruff key is fitted to injection pump shaft. If not, install one.
Fig. 7-25
7-26
2. Push hub onto camshaft of injection pump. Turn up nut and tighten in accordance with Tightening Instructions.
Fig. 7-26
7-27
3. Renew gasket at pump flange.
Fig. 7-27
7-28
4. Install injection pump and tighten down nuts, taking care to position in centre of elongated holes.
Fig. 7-28
7-29
5. Position one of the screws for securing gear and tighten down.
Fig. 7-29
7-30
6. Rotate crankshaft to TDC position, cylinder No. 1.
Fig. 7-30
7. Remove cover of injection pump. Loosen and remove screw securing gear.
7-31
8. Rotate crankshaft until 1st plunger of injection pump is in TDC position.
Fig. 7-31
9. Position other screws securing gear and tighten down.
7-32
10. Install cover of injection pump. Assemble and tighten unions of injection delivery lines so that latter are free from tension.
Fig. 7-32
11. Connect fuel lines and flexible tubing, as well as leak-off lines.
12. Adjust commencement of delivery.
See Section 2.
Removing And Refitting The Distributor-Type Injection Pump (Current Type)
Vee-belt tensioner and cover have been removed.
Dismantling:
1. Set piston of No. 1 cylinder to TDC. Disconnect fuel and injection lines.
7-33
NOTE: Uncovered sockets and pipe connections must be sealed immediately.
Fig. 7-33
7-34
2. Unscrew nut from pump shaft at the pump drive.
Fig. 7-34
3. Remove spring lockwasher.
NOTE: Do not drop spring lockwasher into the housing.
7-35
4. Position device (with sleeve) at the pump drive and pull off drive from the shaft.
Fig. 7-35
NOTE: Do not revolve the crankshaft.
Important:
Starting 1975, the hub has been modified: the thread for tool No. 110340 has been dispensed with.
See: REMOVING AND REFITTING DISTRIBUTOR TYPE INJECTION PUMP (NEW TYPE WITH NEW HUB)
7-36
5. Loosen fastening nuts on flange of distributor-type fuel injection pump and remove pump.
Fig. 7-36
Refitting The Pump
7-37
1. Put in oval gasket. Replace gasket if damaged.
Fig. 7-37
NOTE: When replacing the gasket, be sure to use new gasket of equal thickness.
7-38
2. Make sure that a Woodruff key is provided on the pump camshaft.
Fig. 7-38
7-39
3. Fasten pump to the flange. Be sure to use the correct washers.
Fig. 7-39
4. Screw on nut to the pump drive and tighten.
NOTE: Do not forget the spring lockwasher.
5. Check commencement of fuel delivery. See Setting and Operating Instructions.
7-40
NOTE: The actuating levers of the distributor-type pump for the tractor engine F6L 912 are towards the engine.
Fig. 7-40
Removing And Refitting The Distributor-Type Injection Pump (New Type With New Hub)
Vee-belt tensioner and cover have been removed.
Dismantling:
1. Set piston of No. 1 cylinder to TDC. Disconnect fuel and injection lines.
7-41
NOTE: Uncovered sockets and pipe connections must be sealed immediately.
Fig. 7-41
7-42
2. Unscrew bolts from gear
Fig. 7-42
7-43
3. Loosen fastening nuts on flange of distributor-type fuel injection pump and remove pump.
Fig. 7-43
NOTE: Do not revolve the crankshaft.
7-44
4. Withdraw hub from the pump's camshaft.
Fig. 7-44
Installation:
7-45
1. Make sure that a Woodruff key is provided on the pump camshaft.
Fig. 7-45
7-46
2. Slip hub over camshaft, fit nut and tighten as specified.
Fig. 7-46
7-47
3. Renew pump flange gasket.
Fig. 7-47
7-48
4. Remove cover (arrowed in Fig. 7-48) from pump and turn camshaft until line mark and pointer agree.
5. Install pump and secure nuts with slots in centre position.
Fig. 7-48
Setting And Operating Instructions For The Distributor- Type Pump
1. Commencement of Delivery
The methods usually applied to in-line pumps for determining the commencement of delivery (closure of suction hole) are not suitable for the distributor-type pump. At a total stroke of only 2.5 - 2.8 mm of the distributor-type pump plunger the delivery commences at a plunger stroke of approx. 0.2 - 0.4 mm, i.e. within a range difficult to be measured. For this reason Bosch has introduced an auxiliary value.
Instead of setting the commencement of delivery as usual, a stroke of 1 mm of the plunger is associated to a certain crankshaft angle before TDC.
In colloquial language this angle value is defined as follows:
commencement of delivery of x° crankshaft angle before TDC at 1 mm stroke.
Consequently, this value adopted for the commencement of delivery is not identical with any of the values known on in-line pumps.
2. Setting the Commencement of Delivery
Turn the crankpin of No. 1 cylinder into a position corresponding to the respective angle of commencement of delivery (x° crankshaft angle before TDC at 1 mm stroke), i.e. 16 ± 1° before TDC in the present case.
Loosen the hex. bolts connecting the drive gear (1) with the hub (2). Remove cover of setting window (3) so that the lifting disc (4) and the pointer (5) become visible. Turn pump shaft in the direction of engine rotation until the mark on the lifting disc is partly covered by the pointer (5). Hold pump shaft in this position and re-tighten the hex. bolts connecting the drive gear (1) with the hub (2).
This position corresponds to 1 mm stroke when delivering fuel for the injection line to No. 1 cylinder, via connection (B).
Check setting by turning the crankshaft backwards (approx. 90° against engine sense of rotation) and then in the direction of engine rotation until the mark of the lifting disc (4) is partly covered by the pointer (5). Crankpin of No. 1 cylinder must now be at 16° before TDC.
Under no circumstances must the fastening screw of the pointer (5) be released and the pointer be disturbed. This would violate the setting of the commencement of delivery (1 mm stroke in relation to No. 1 cylinder) and a fresh setting could only be made with a special measuring instrument.
3. Venting of Distributor-type Pump
Slacken overflow valve (6) until fuel escapes over the thread and then tighten valve again.
Loosen venting screw (7) and re-tighten as soon as fuel escapes here.
When engine does not start, repeat venting procedure.
The venting takes a little longer than with an in-line pump due to the larger fuel quantity in the distributor-type pump. The hollow bolt holding the overflow valve (6) which is located at the highest point of the pump, must never be replaced by an ordinary banjo bolt.
4. Operation of the Distributor-type Pump
The stop of the speed control lever (8) (upper lever) is set and lead-sealed to the permissible operating speeds.
The lower lever (9), i.e. the stopping and starting lever, when moved into the operating position, must definitely rest against the adjustable full load stop (10). When this lever is pulled against the spring-loaded stop until the latter becomes blocked, the delivery drops to Zero and by this action the engine can be shut off, (stop position).
5. Starting the cold Engine using additional Fuel
When starting the engine, the well-known instructions must be followed. When actuating the starter, the lever (9) must be moved manually - by means of the control cable-away from the blocking up position towards the spring-loaded stop (11) (starting position) until a resistance is felt on the control cable, and it must be kept there until the engine has been started and is running well. With the control cable being in starting position, the additional fuel quantity required for starting is injected and is reduced again in relation to and dependent on a speed of 500 - 700 rpm. When the control cable is kept in starting position, the engine will run at an idling speed of 600 - 1800 rpm, depending on temperature and pump control. When having pushed the control cable back into running position, which can be done after about 15 - 30 sec. with a cold started engine, the engine speed is reduced automatically to low idling. Make sure that the control cable is returned to running position quickly and completely, because there is a range of reduced fuel delivery between the starting position and the full load stop (10).
When the control cable is pushed back too early, the engine "dies". Such being the case, the starting procedure must be repeated.
With lever (9) being in starting position, the accelerator pedal and/or the speed control lever must not be actuated, since otherwise the fuel delivery will drop to Zero - due to the pump design - and the engine will stop. An engine forced to mas. speed cannot be kept running by subsequent pulling of the control cable for obtaining additional fuel quantity, but will stop.
6. Full-load Quantity for Starting a warmed-up Engine
When the engine is warmed-up, it is not necessary to operate the lever (9) for additional fuel.
7. Stopping the Engine
For stopping the engine, the starting and stopping lever (9) must be pulled beyond the starting position until it rests firmly against the stop. When pulling the lever slowly, the engine will speed up again before stopping.
8. Operating the Tractor
The hydraulic governor of the distributor-type pump functions in the same manner as a mechanical governor (RSV governor) of an in-line pump. It is, however, more sensitive to response than the mechanical governor.
Pump Illustrations
Fuel Circuit Of Distributor - Type Pump
Checking The Fuel-Injection Pump Drive And Replacing Components (as from 3 cylinder engine)
1. Check the gearwheel and hub or injection timer. If necessary, dismantle the gearwheel from the hub or from the injection timer.
2. Renew the defective component.
7-49
2.1 Assemble the gearwheel and hub so that the punch mark registers with the groove in the hub.
Fig. 7-49, right
2.2 Assemble the gearwhell to the injection timer so that the recess in the former registers with the groove in the hub.
Fig. 7-49, left
Important:
As from 1975, the hub was modified in the case of rigid drive.
7-50
2.3 In the case of in-line injection pump, mount gearwheel onto steel hub.
Fig. 7-50, right
2.4 In the case of distributor injection pump, mount gearwheel reversed onto the hub.
Fig. 7-50 left
NOTE: Observe markings and angular degrees.
Dismantling And Installing Injectors
Dismantling:
1. Dismantle leak-off line to injector. Disconnect injection delivery line on injection.
2. Dismantle stirrup and remove thrust piece.
7-51
3. Remove injector using extracting device No. 150800.
Fig. 7-51,
Attention:
In addition, use threaded piece No. 110050 in case of lateral connection of injection delivery line.
Fig. 7-51, left
Use extractor No. 110030 in case of top connection of injection delivery line.
Fig. 7-51, right
7-52
On FL 912 W remove injector by special wrench No. 110010 plus insert No. 110020.
Fig. 7-52
7-53
4. Remove joint washer from injector or from cylinder head, as the case may be. (Extractor No. 120630)
Fig. 7-53, left
In case of FL 912 W, remove heat insulating plate (using, for example, bent wire).
Fig. 7-53, right
Installing:
7-54
1. Stick new joint washer with grease (graphited side facing towards injector).
Fig. 7-54
NOTE: On FL 912 install heat guard as shown.
Fig. 7-53, right
2. Install injector.
7-55
3. Install thrust piece and place stirrup in position.
Fig. 7-55, left
4. Place washer with convex side facing stirrup and screw on nut.
(See Specification Data)
5. On FL 912 W align injector to injection pipe.
Fig. 7-55, right
7-56
6. Tighten injector by special wrench No. 110010 plus insert No. 110020.
Fig. 7-56
7. Tighten injector and fit leak-oil line with new sealing rings.
Removing And Refitting Injector On Engine Provided With Exhaust Air Heating
Preliminary work:
Injector is removed.
1. Stick by means of grease sealing ring to injector and insert the latter in the cylinder head.
7-57
2. Slip rubber seal on injector and the vertical pin (see arrow) for fixture.
Fig. 7-57
7-58
3. Apply leak oil pan (arrow). Slip spring and spacer sleeve on pin for fixture.
Fig. 7-58
4. Apply clamping piece and fixture.
5. Apply washer the curved side of which must show towards fixture; screw on nut. See Tightening Instructions.
Removing And Fitting The Injector Nozzle (direct injector)
The injector has been removed.
Removal:
7-59
1. Unscrew cap from the nozzle holder.
Fig. 7-59
2. Remove the nozzle together with needle, intermediate piece, plunger, spring and shims.
3. Wash all parts in clean diesel fuel and blow out with compressed air.
7-60
4. The nozzle needle and the nozzle body are lapped together and should neither be mixed up nor replaced separately. Do not touch the nozzle needle seating surface which is coated with protective grease. Holding the nozzle vertically, the nozzle needle must be allowed to slide slowly and smoothly on its seating under its own weight.
Fig. 7-60
5. If the nozzle needle does not slide smoothly, wash with fuel again and replace if necessary.
7-61
6. Check the seating surfaces and centering pins of the intermediate piece for wear and to ensure that they seat properly.
Fig. 7-61
Fitting:
7-62
7. Insert the existing shims into the nozzle holder.
Fig. 7-62
Note for Refitment:
Spraying pressure is increased by fitting shims and is reduced by removing them.
7-63
8. Insert the pressure spring in the nozzle holder.
Fig. 7-63
7-64
9. Insert the plunger with the spigot facing the pressure spring.
Fig. 7-64
7-65
10. Insert the intermediate piece with the guide pins into the holes in the nozzle holder.
Fig. 7-65
7-66
11. Locate the nozzle on the intermediate piece by means of the holes and tighten the screwcap on the nozzle holder.
Fig. 7-66
Note for Refitments:
Note the type of nozzle.
12. Adjust the nozzle according to the Chapter "Checking and Adjustment".
Exploded Views
