Information injection-pump assembly
BOSCH
9 400 619 751
9400619751
ZEXEL
101441-9650
1014419650
NISSAN-DIESEL
1679090277
1679090277
Rating:
Service parts 101441-9650 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660043G03
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101441-9650
as INJECTION-PUMP ASSEMBLY
Include in #2:
105856-5460
as _
Cross reference number
BOSCH
9 400 619 751
9400619751
ZEXEL
101441-9650
1014419650
NISSAN-DIESEL
1679090277
1679090277
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
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
2.3
2.25
2.35
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
A
Rack position
11.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
38.6
37.6
39.6
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.1+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.9
9.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3
2.5
3.5
Timer adjustment_04
Pump speed
r/min
1800
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=8 RAL=14.7-0.3mm N1=1600r/min N2=1000r/min
----------
----------
K=8 RAL=14.7-0.3mm N1=1600r/min N2=1000r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=34deg+-5deg b=26deg+-5deg
----------
----------
a=34deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=53deg+-5deg
----------
----------
a=12deg+-5deg b=53deg+-5deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Maximum no-load speed (r/min)
LABEL9:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)At high idle rack position L
----------
L=6.2mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- r5=- r6=- Q1=- Q2=38.6+-1mm3/st Q3=- Q4= Q5= Q6= c1=+-4% c2=+-4% c3=+-4% c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=19 a25=- a26=- a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=950r/min r25=- r26=- r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=1020+-23r/min R25=- R26=- R27=- R28=-
----------
L=6.2mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- r5=- r6=- Q1=- Q2=38.6+-1mm3/st Q3=- Q4= Q5= Q6= c1=+-4% c2=+-4% c3=+-4% c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=19 a25=- a26=- a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=950r/min r25=- r26=- r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=1020+-23r/min R25=- R26=- R27=- R28=-
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(100deg)
----------
aa=18deg
----------
a=(100deg)
Information:
Shutdowns
A shutdown secures the fuel and a shutdown secures the air to the engine. A fuel shutoff solenoid may be located in the fuel actuator. The fuel shutoff solenoid is energized. The injector is driven to the off position. This secures the fuel.The air shutoff solenoid secures the air. When this solenoid is activated compressed air flows to the air damper. The air releases a pin. When the pin is released, a spring closes the air damper. This secures the combustion air supply from the turbochargers to the aftercooler.Note: The air damper must be MANUALLY reset before the engine can be restarted. The Marine Engine Control Panel must also be reset with the "RESET" switch before the MMS will allow starting. The panel may not be reset until the engine has stopped rotating. Determine the cause of the shutdown and correct the problem prior to engine operation.
Table 2
Shutdowns of the Marine Monitoring System
Description Sensor Location
Group Part Number (1) Set Point Source of the Alarm
Pressure
Low Oil Pressure 142-5916 or 146-9438 Block 1
105 kPa (15 psi) @LS
260 kPa (38) @HS Low Speed Oil Contactor or High Speed Oil Contactor, or the Lube Oil Filter Outlet Pressure Transducer
High Crankcase Pressure 147-2369 In-line 142-5919 Vee
1 kPa (.15 psi) Crankcase pressure contactor
Temperature
High Jacket Water Outlet Temperature 142-5916 or 146-9438 Block 4
109 °C (228 °F) Jacket Water Contactor or Optional Transducer
Miscellaneous
Oil Mist Detector Various Contact Closure Oil Mist Detector - Not in all engines
Overspeed 146-5522, 146-5523, 146-5524, 146-5525 113% of Rated Speed Engine Speed Switch and MMS
Metal Particle Detection Basic Engine Metal Particles in Oil Plus 5 Seconds Metal Particle Detector
( 1 ) The group part numbers are provided for reference only. For individual part numbers see Reference Information, "Reference Parts Information".Low Speed - The engine speed is below 75% of the rated engine speed.High Speed - The engine speed is above 75% of the rated engine speed.The "Sensor Failure Alarm" Screen
The "Sensor Failure Alarm" screen is displayed when unexpected signals are received by the PLC. The alarm monitors sensors which can produce alarms or shutdowns.
Table 3
Sensor Failure Alarms for the Marine Monitoring System
Description Sensor Location
Group Part Number (1) Set Point Source of the Alarm
RTD/PT 100 Failures Various
< -50 °C (-58 °F) or
> 150 °C (302 °F) Lube oil, After Cooler/Oil Cooler, Jacket Water, and Inlet Manifold Temperatures
Thermocouples Various
< -50 °C (-58 °F) or
> 700 °C (1292 °F) Individual Cylinder, Pre-Turbine, and Stack Thermocouples
4-20mA Transducers Various < 3.5 mA or > 20.15 mA Engine Speed Transducer, Lube Oil and Fuel pressure transducers
Contactors Various No signal
A shutdown secures the fuel and a shutdown secures the air to the engine. A fuel shutoff solenoid may be located in the fuel actuator. The fuel shutoff solenoid is energized. The injector is driven to the off position. This secures the fuel.The air shutoff solenoid secures the air. When this solenoid is activated compressed air flows to the air damper. The air releases a pin. When the pin is released, a spring closes the air damper. This secures the combustion air supply from the turbochargers to the aftercooler.Note: The air damper must be MANUALLY reset before the engine can be restarted. The Marine Engine Control Panel must also be reset with the "RESET" switch before the MMS will allow starting. The panel may not be reset until the engine has stopped rotating. Determine the cause of the shutdown and correct the problem prior to engine operation.
Table 2
Shutdowns of the Marine Monitoring System
Description Sensor Location
Group Part Number (1) Set Point Source of the Alarm
Pressure
Low Oil Pressure 142-5916 or 146-9438 Block 1
105 kPa (15 psi) @LS
260 kPa (38) @HS Low Speed Oil Contactor or High Speed Oil Contactor, or the Lube Oil Filter Outlet Pressure Transducer
High Crankcase Pressure 147-2369 In-line 142-5919 Vee
1 kPa (.15 psi) Crankcase pressure contactor
Temperature
High Jacket Water Outlet Temperature 142-5916 or 146-9438 Block 4
109 °C (228 °F) Jacket Water Contactor or Optional Transducer
Miscellaneous
Oil Mist Detector Various Contact Closure Oil Mist Detector - Not in all engines
Overspeed 146-5522, 146-5523, 146-5524, 146-5525 113% of Rated Speed Engine Speed Switch and MMS
Metal Particle Detection Basic Engine Metal Particles in Oil Plus 5 Seconds Metal Particle Detector
( 1 ) The group part numbers are provided for reference only. For individual part numbers see Reference Information, "Reference Parts Information".Low Speed - The engine speed is below 75% of the rated engine speed.High Speed - The engine speed is above 75% of the rated engine speed.The "Sensor Failure Alarm" Screen
The "Sensor Failure Alarm" screen is displayed when unexpected signals are received by the PLC. The alarm monitors sensors which can produce alarms or shutdowns.
Table 3
Sensor Failure Alarms for the Marine Monitoring System
Description Sensor Location
Group Part Number (1) Set Point Source of the Alarm
RTD/PT 100 Failures Various
< -50 °C (-58 °F) or
> 150 °C (302 °F) Lube oil, After Cooler/Oil Cooler, Jacket Water, and Inlet Manifold Temperatures
Thermocouples Various
< -50 °C (-58 °F) or
> 700 °C (1292 °F) Individual Cylinder, Pre-Turbine, and Stack Thermocouples
4-20mA Transducers Various < 3.5 mA or > 20.15 mA Engine Speed Transducer, Lube Oil and Fuel pressure transducers
Contactors Various No signal