Information injection-pump assembly
ZEXEL
101491-9105
1014919105
Rating:
Cross reference number
ZEXEL
101491-9105
1014919105
Zexel num
Bosch num
Firm num
Name
101491-9105
INJECTION-PUMP ASSEMBLY
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
3.4
3.35
3.45
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
11.21+-0
.02
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.8
56.3
57.3
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
9.6+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9
7
11
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
11.21+-0
.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
56.8
56.3
57.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
11.48+-0
.5
Pump speed
r/min
1700
1700
1700
Average injection quantity
mm3/st.
68.9
66.9
70.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
11.32+-0
.5
Pump speed
r/min
625
625
625
Average injection quantity
mm3/st.
42
40
44
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
H
Rack position
9.3+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7
6.5
7.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1350+-25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1700
Advance angle
deg.
3.5
3.2
3.8
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: R1, speed N1
(3)Torque cam set point
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------
----------
T1=C83 R1=+-0.02mm N1=+-3r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=41deg+-3deg
----------
aa=(9.3)mm bb=325r/min
----------
a=20deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=40deg+-5deg
----------
----------
a=40deg+-5deg b=40deg+-5deg
0000001501 GOV RACK POSITION CONFIRM
Confirm the governor adjustment rack position.
Standard point A
Set the torque cam B.
(C) Confirmation
(D) Remarks
(N): Speed of the pump
(R) Rack position (mm)
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-0.05mm
----------
----------
Na=1000r/min Nb=625r/min Nc=1800r/min Nd=1700r/min Ne=1400r/min Nf=450r/min Ra=11.21+-0.02mm Rb=11.32+-0.02mm Rc=11.27+-0.1mm Rd=11.48+-0.05mm Re=11.39+-0.05mm Rf=11.46+-0.05mm
0000001601 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=(11.21)mm Rb=(10.8)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=56.8+-0.5cm3/1000st Q2=48.8+-1cm3/1000st
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
This Program must be administered as soon as possible. When reporting the repair, use "PI3147" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3147" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.
Completion Date
November 30, 1998Termination Date
November 30, 1998Problem
Certain 3116 and 3126 2-Valve Engines built from January 28 through February 6, 1998 with CBS heads are suspect to have improper installation of the brass injector sleeve.
Affected Product
Model & Identification Number
3116 (2WG6414-6426 5EN01269, 5EN1270, 5EN1273-1280, 5EN1282 4KG7773-7795 4KG31268NM3029-3043 9ZR771-774 )
Parts Needed
1 - 1192940 Gasket* - 1193061 Sleeve*(as required)Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1. Check to see if the head is supplied by CBS or Gosselies. The part number is located on the front of the head on the governor side beside the lifting eye, just above the front cover. In Marine applications, it is best viewed using a light to look between the expansion tank and heat exchanger.If it is a dot-matrix, then the head is from Gosselies. If the part number is stamped, then it is from CBS.
If the head is from Gosselies (dot-matrix part number), then the engine is good and no further work is needed.
If the head is from CBS (Stamped part number) then further inspection/rework is required.
2. If the head is from CBS, remove the valve cover.3. Using a sliding caliper, align the caliper vertically using the edge of the injector spring, measure and record the distance from the timing ledge on the injector to the top face of the head for each cylinder. This measurement will be in the range of 8.39 mm but can vary from engine to engine.4. If the variation from cylinder to cylinder on the same engine is less than 0.40 mm, then the engine is good. Re-install the valve cover. No further inspection is necessary.5. If the variation from cylinder to cylinder on the same engine is greater than 0.40 mm, recheck to verify measurements, if the difference is still greater than 0.40 mm, proceed to Step 6.6. Remove all (6) injectors. Using a depth gage with flat end and a 0.75 inch diameter steel ball dropped into the sleeve, check and record the distance from the top face of the head to the top of the steel ball. This measurement should be 2.583 0.18 inches (65.61 0.46 mm).7. Remove the injector sleeve on any cylinder that the measurement from step 6 is less than 2.565 inch (65.15 mm) and
Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.
Completion Date
November 30, 1998Termination Date
November 30, 1998Problem
Certain 3116 and 3126 2-Valve Engines built from January 28 through February 6, 1998 with CBS heads are suspect to have improper installation of the brass injector sleeve.
Affected Product
Model & Identification Number
3116 (2WG6414-6426 5EN01269, 5EN1270, 5EN1273-1280, 5EN1282 4KG7773-7795 4KG31268NM3029-3043 9ZR771-774 )
Parts Needed
1 - 1192940 Gasket* - 1193061 Sleeve*(as required)Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1. Check to see if the head is supplied by CBS or Gosselies. The part number is located on the front of the head on the governor side beside the lifting eye, just above the front cover. In Marine applications, it is best viewed using a light to look between the expansion tank and heat exchanger.If it is a dot-matrix, then the head is from Gosselies. If the part number is stamped, then it is from CBS.
If the head is from Gosselies (dot-matrix part number), then the engine is good and no further work is needed.
If the head is from CBS (Stamped part number) then further inspection/rework is required.
2. If the head is from CBS, remove the valve cover.3. Using a sliding caliper, align the caliper vertically using the edge of the injector spring, measure and record the distance from the timing ledge on the injector to the top face of the head for each cylinder. This measurement will be in the range of 8.39 mm but can vary from engine to engine.4. If the variation from cylinder to cylinder on the same engine is less than 0.40 mm, then the engine is good. Re-install the valve cover. No further inspection is necessary.5. If the variation from cylinder to cylinder on the same engine is greater than 0.40 mm, recheck to verify measurements, if the difference is still greater than 0.40 mm, proceed to Step 6.6. Remove all (6) injectors. Using a depth gage with flat end and a 0.75 inch diameter steel ball dropped into the sleeve, check and record the distance from the top face of the head to the top of the steel ball. This measurement should be 2.583 0.18 inches (65.61 0.46 mm).7. Remove the injector sleeve on any cylinder that the measurement from step 6 is less than 2.565 inch (65.15 mm) and
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101491-9105
INJECTION-PUMP ASSEMBLY