Information injection-pump assembly
BOSCH
9 400 619 581
9400619581
ZEXEL
101401-9164
1014019164
Rating:
Service parts 101401-9164 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
TM01 13 H50
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 581
9400619581
ZEXEL
101401-9164
1014019164
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
131424-3420
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-3-4-2
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68.5
68
69
Max. variation between cylinders
%
0
-2.5
2.5
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
325
325
325
Average injection quantity
mm3/st.
9.7
7.7
11.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68.5
68
69
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
86.2
82.2
90.2
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
60.9
56.9
64.9
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
170
170
Fixing the lever
*
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1475
Advance angle
deg.
4
3.5
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.
----------
T1=H04
----------
----------
T1=H04
----------
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=20deg+-5deg b=(29deg)+-3deg
----------
aa=36mm
----------
a=20deg+-5deg b=(29deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stop adjuster screw
----------
aa=39mm
----------
a=14deg+-5deg b=(24deg)+-5deg
----------
aa=39mm
----------
a=14deg+-5deg b=(24deg)+-5deg
0000001501 LEVER
CL:Center line of camshaft
ST:Stop adjuster screw
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
1. Stop lever adjustment outline
(1)After completing all adjustments, confirm that the lever angle is within the specifications in the normal position.
(2)Set the speed lever in the full speed position.
(3)At pump speed Na, position the rack at non-injection position Ra.
(4)Set the stop adjusting screw to fix the speed lever in the idling position.
(5)Confirm that there is no injection at pump speed Nb.
----------
Na=1550r/min Nb=325r/min Ra=7.2-0.5mm
----------
----------
Na=1550r/min Nb=325r/min Ra=7.2-0.5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(140deg)
----------
aa=11deg
----------
a=(140deg)
Information:
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed.
1. Remove the carbon from the top inside surface of the cylinder liners.2. Turn the crankshaft until two pistons are at bottom center.3. Remove bearing caps (1) from the two connecting rods. 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pistons (2). Keep each cap with its connecting rod.5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons & Connecting Rods
1. Put clean engine oil on the piston rings, connecting rod bearings and cylinder liners. 2. Put two pistons in position opposite of each other in the correct bore of the block. Install pistons (1) with Tool (A).
Make sure that the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.
For more detail about the installation of connecting rod bearings, see Remove & Install Connecting Rod Bearings.
Do not use an impact wrench to tighten the nuts the additional 120 degrees when the bearing clearance is checked.
3. Check the bearing clearances with Plastigage.4. Put 2P-2506 Thread Lubricant on bolts (5). Install caps (3) and the nuts finger tight. Tighten each nut to a torque of 81 8 N m (60 6 lb ft). Put a mark across the nuts and bolts. Tighten each nut 120 degrees more.5. Check the side clearance between two connecting rods on the same crankshaft journal. The clearance must be 0.28 to 0.84 mm (.011 to .033 in) for new rods.6. Do Steps 1 through 5 for the remainder of the pistons.End By:a. install piston cooling tubesb. install oil pumpc. install cylinder headsDisassemble & Assemble Pistons & Connecting Rods
Start By:a. remove pistons and connecting rods 1. Remove bearings (3) from the connecting rod and connecting rod cap. The new style retainer rings allow the use of pliers to remove retainer ring (1).2. Remove retainer ring (1) with Tool (A) or pliers.3. Remove pin (2) and connecting rod (4) from the pistons. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See Use Of Piston Pin Bearing Removal & Installation Tools, Special Instructions, SMHS7295-02.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260° C (350° to 500° F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of Tooling (C). Put a new rod pin bearing (6) on the adapter part of Tooling (C). The old bearing is pushed out by Tooling (C) as the new bearing is installed.7. Use Tooling (C) to push the new bearing into the connecting rod until the push adapter of Tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the