Bosch P7100 injection pump

[fitterski]

I pulled this pump offa the ram truck engine I'm rebuilding. The pro shop did not overhaul it per-se but 'looked at it' and it so happens claimed to have 'fixed a minor snag'. I'm in the process of cleaning it up before returning it to the parent engine and noticed that they left two little plugs in two little holes on the face just above the conical gear shaft.



What are these holes for? I figure I should remove the plugs but there may be a proper time to do so and a wrong time. I haven't been able to find a service type manual that explains the pump in detail (what does what, how, when, why sort of thing with illustrations).

 

[thepumpguysc]

YES.. REMOVE THE PLUGS..
THOSE are the oil drain plugs back to the engine..
They put them in there to keep the excess oil from dripping all over you & your car..
They are JUST FOR travel.. NOT installation.

 

[fitterski]

YES.. REMOVE THE PLUGS..
THOSE are the oil drain plugs back to the engine..
They put them in there to keep the excess oil from dripping all over you & your car..
They are JUST FOR travel.. NOT installation.

I was afraid so, seeing that the shaft is not keyed I would have put them under it.

 

[fitterski]

Re: Bosch P7100 injection pump 3 other Q's

1
On the fuel "Supply" banjo there's a cardboardish paper sleeve, what's its purpose and where does it go?


2
What does the #1 "start" position do, just flood with loads of extra fuel?

3
The shutdown lever is mechanically sprung OUT of shutdown position #3. I presume the truck solenoid has 2 coils one of which holds the #2 "run" position, both of them pull all the way to #1 "start", but what forces the lever to the #3 "shutdown" position? Are both solenoid coils momentarily reversed and powered?

 

[thepumpguysc]

. same as the plugs by the camshaft, just wider.. throw away..
There are ONLY 2 positions on the shut off.. run & shut down..
I don't know where your getting your information from.. but only 2.
The shut off solenoid is spring loaded to the shut off position.. so when power is cut, it springs to shut off..
Yes, the solenoid has 2 circuits.. PULL & HOLD.. On starting[pull] it has a VERY heavy amp draw & then switches to low[hold] AFTER starting..

Are you familiar w/ the pump to engine timing for the install??
IF NOT.. you better get some help.!!! The pump & engine SHOULD HAVE BEEN timed before pump removal..
OH WAIT> you said your doing an engine O/H?? I guess it didn't matter then.. BUT>> BOTH HAVE TO BE IN TIME BEFORE INSTALL..
Your only gonna wanna do it ONCE.. that thing is awful heavy, to be leaning over wrestling it around.. if ya know what I mean..
Good Luck.. TPG

 

[fitterski]

. same as the plugs by the camshaft, just wider.. throw away..

It's more like a paper sleeve, there to protect the banjo I guess?

There are ONLY 2 positions on the shut off.. run & shut down..
I don't know where your getting your information from.. but only 2.
The shut off solenoid is spring loaded to the shut off position.. so when power is cut, it springs to shut off..
Yes, the solenoid has 2 circuits.. PULL & HOLD.. On starting[pull] it has a VERY heavy amp draw & then switches to low[hold] AFTER starting..

The spring-loaded shutoff position is straight forward, but when you come out of that to the detent then the lever can still move more in the same direction. I guess once it's open it's open.

Are you familiar w/ the pump to engine timing for the install??
IF NOT.. you better get some help.!!! The pump & engine SHOULD HAVE BEEN timed before pump removal..
OH WAIT> you said your doing an engine O/H?? I guess it didn't matter then.. BUT>> BOTH HAVE TO BE IN TIME BEFORE INSTALL..
Your only gonna wanna do it ONCE.. that thing is awful heavy, to be leaning over wrestling it around.. if ya know what I mean..
Good Luck.. TPG

When I pulled it I didn't yet know that I was gonna send it to the shop so yes, I timed it i.e. TDC and the gear-pin fitted onto the tongue/tab in the pump viewer. I don't know if the tests made on it involved rotation, most probably they did, but I got it back with the peg in the stowed position. I haven't opened it up yet to see if it's properly on the little tab.

 

[fitterski]

Re: Bosch P7100 injection pump ..plumbing Q's

I try to run a clean shop and have cleaned the 1/8" thick black grime off the tubing but need to identify some of them.

1
Aneroid says Air-Pressure, presumably ambient, but there are 2 connectors (#1 and #2) on the attached fuel line. What's involved here, what do they connect to? Is this fuel that is relieved @ the AFC and then routed back to the filter or to the return plumbing?

2
The oil line comes from the block tap (Oil Port) just below the pump, but where does #3 go, to the truck gauges? I have none of the host vehicle's wires or tubing.


http://trixtar.org/temp-pub-buffer/all-that-plumbing-labs.jpg

The 175hp engine is dated 19940110 (presumably 1994-Jan-10) so it may have gone into a 1995/96 Ram.

 

[thepumpguysc]

I've never seen the oil line w/ 2 fittings before. BUT> that is your FEED line, for engine lube oil TO the injection pump..
Personally, I would take the middle fitting out of the system.. The oil pressure gauges aren't gonna read from there.

The aneroid line should hook up to a fitting coming off the air intake manifold. NO FUEL.!! only AIR.. your thinking of a Cummins PT system..

The fuel fitting off the back side IS the overflow & goes back to the tank or filter.

You shoulda told'm to turn it up 10-15%.. that 175 is gonna be "a dog".. its no problem getting 200hp out of the same pump..
I did a pump for a fella that had more money than brains.. & he was experimenting w/ a street legal race truck.. Cummins B series.. same engine as yours in a ram p/u truck.
He didnt care about a "governor" & wanted me to "disable it".. Well, you cant actually do that, but you can get pretty close.Lol
I did the pump, took care of the governor & put as much fuel to it as I could & still be able to achieve "low idle"..
He took me for a ride.. WOW..
We went down the hiway 75MPH, he shifted down to a lower gear & stomped on the gas.. it spun the tires about 30 yards & fish-tailed sideways down the interstate.!!! What a nut..

 

[fitterski]

I've never seen the oil line w/ 2 fittings before. BUT> that is your FEED line, for engine lube oil TO the injection pump..
Personally, I would take the middle fitting out of the system.. The oil pressure gauges aren't gonna read from there.

It could be a low-oil shutdown switch, I can plug it up and use it if I need it when I need it.

The aneroid line should hook up to a fitting coming off the air intake manifold. NO FUEL.!! only AIR.. your thinking of a Cummins PT system..

I looked and all I can find is 2 plumbing ports of about that size on the intake manifold side of the head. The other end with the small hose then remains a mystery.

You shoulda told'm to turn it up 10-15%.. that 175 is gonna be "a dog".. its no problem getting 200hp out of the same pump..
I did a pump for a fella that had more money than brains.. & he was experimenting w/ a street legal race truck.. Cummins B series.. same engine as yours in a ram p/u truck.
He didnt care about a "governor" & wanted me to "disable it".. Well, you cant actually do that, but you can get pretty close.Lol
I did the pump, took care of the governor & put as much fuel to it as I could & still be able to achieve "low idle"..
He took me for a ride.. WOW..
We went down the hiway 75MPH, he shifted down to a lower gear & stomped on the gas.. it spun the tires about 30 yards & fish-tailed sideways down the interstate.!!! What a nut..

Hahahaha, that must have been a show! I'm having a hard time getting 'complete' power curves for cummins engines, they don't seem to think them important. Since next winter I'm only going to mount this engine in the existing snow blower I won't be running it above torque rpm around 1500-1700 initially. I don't know enough about diesels but more fuel will just give you more RPM, no? I could get more fuel to burn if I also raise the boost but I'm not ready to try that just yet, reason being that the existing rig was made for about 50hp and has a gearbox through-shaft of 1-1/2 inch I think. I'll have to tip-toe it until I get to see what we have 'under the hood' all-in-all. I'm actually thinking of not waiting to see the gearbox break when I need it most but swapping in one with a 2 or 2-1/2 inch shaft.

If anyone with a 175hp standard tranny ram has words about the pump connections I'd love to hear from you. I don't know themn trucks and don't have the one this engine was in.

 

[fitterski]

Re: Bosch P7100 injection pump ..plumbing Q's

2
The oil line comes from the block tap (Oil Port) just below the pump, but where does #3 go, to the truck gauges? I have none of the host vehicle's wires or tubing.

In case anyone might be googling for this info in the future, the last part of the oil line goes to the steering-pump/vacuum-pump bearings.