Information injection-pump assembly
BOSCH
9 400 619 640
9400619640
ZEXEL
101401-9211
1014019211
MAZDA
TMSK13800A
tmsk13800a
Rating:
Service parts 101401-9211 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
9 400 619 640
9400619640
ZEXEL
101401-9211
1014019211
MAZDA
TMSK13800A
tmsk13800a
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
11.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
60
59.5
60.5
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
425
425
425
Average injection quantity
mm3/st.
10.5
8.5
12.5
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(11.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
60
59.5
60.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.65
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
49.1
45.1
53.1
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
98
98
113
Fixing the lever
*
Rack limit
*
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
1100
Advance angle
deg.
1.5
1
2
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.
(3)RACK LIMIT
----------
T1=J02
----------
----------
T1=J02
----------
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=15deg+-5deg b=(36deg)+-3deg
----------
aa=36mm
----------
a=15deg+-5deg b=(36deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=39mm
----------
a=40deg+-5deg b=36.5deg+-5deg
----------
aa=39mm
----------
a=40deg+-5deg b=36.5deg+-5deg
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=9deg
----------
a=(130deg)
----------
aa=9deg
----------
a=(130deg)
Information:
start by: a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A). 2. Remove the bolt (1) from the cover. Turn the injection pump camshaft until the timing pin (B) can be installed in the camshaft.3. Install tool (C) in the threads of the sleeve (3). Tighten the bolt until the sleeve can be removed.4. Remove the four bolts (4) that hold the body to the housing.5. Remove the body (2) from the housing. 6. Remove the idler gear (5) from the body.7. Remove the O-ring seal (6) from the body. Remove the two lip type seals (7) from the body. 8. Remove the drive gear (9) from the shaft.9. Remove the key (8) from the shaft.Install Fuel Transfer Pump
1. Install the key (1) and the drive gear (2) on the shaft.2. Put 5S1454 Sealing Compound on the outside diameter of the seals. 3. Install the inner seal in the body with the lip of the seal toward the inside with tooling (A).4. Install the outer seal in the body with the lip of the seal toward the outside with tooling (B).5. Remove the extra sealing compound from the body and the seals after installation. 6. Install the O-ring seal (4) and the idler gear (3) in the body. 7. Install the body (5) on the housing. 8. Install the four bolts (7) that hold the body to the housing.9. Put the timing pin (D) in position to keep the camshaft from turning.10. Put the sleeve (6) on the camshaft. 11. Tighten the sleeve into position on the shaft with 4B4280 Washer of tooling (C) approximately .25 in. (6.4 mm). Tighten the sleeve the remainder of the way with the 4N3371 Washer. The 4N3371 Washer is the washer which is on the tachometer drive bolt.
Do not hit the sleeve to install. Damage to governor will result.
12. The end play of the camshaft must be .023 .018 in. (0.58 0.46 mm) after sleeve (6) is installed.end by: a) install fuel injection pump housing and governor
1. Install the key (1) and the drive gear (2) on the shaft.2. Put 5S1454 Sealing Compound on the outside diameter of the seals. 3. Install the inner seal in the body with the lip of the seal toward the inside with tooling (A).4. Install the outer seal in the body with the lip of the seal toward the outside with tooling (B).5. Remove the extra sealing compound from the body and the seals after installation. 6. Install the O-ring seal (4) and the idler gear (3) in the body. 7. Install the body (5) on the housing. 8. Install the four bolts (7) that hold the body to the housing.9. Put the timing pin (D) in position to keep the camshaft from turning.10. Put the sleeve (6) on the camshaft. 11. Tighten the sleeve into position on the shaft with 4B4280 Washer of tooling (C) approximately .25 in. (6.4 mm). Tighten the sleeve the remainder of the way with the 4N3371 Washer. The 4N3371 Washer is the washer which is on the tachometer drive bolt.
Do not hit the sleeve to install. Damage to governor will result.
12. The end play of the camshaft must be .023 .018 in. (0.58 0.46 mm) after sleeve (6) is installed.end by: a) install fuel injection pump housing and governor