Information injection-pump assembly
BOSCH
F 01G 09U 01V
f01g09u01v
ZEXEL
101491-9724
1014919724
MAZDA
SLTP13800D
sltp13800d
Rating:
Service parts 101491-9724 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
SL50 13 H50A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 01V
f01g09u01v
ZEXEL
101491-9724
1014919724
MAZDA
SLTP13800D
sltp13800d
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
11.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
59.3
58.8
59.8
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
-
Rack position
10.1+-0.
5
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
10
8
12
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
59.3
58.8
59.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.3
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
72.4
68.4
76.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.75
)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
41.1
37.1
45.1
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
75
70
85
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
(1500)+-
25
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
(1750)
Advance angle
deg.
3
2.7
3.3
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=D21
----------
----------
T1=D21
----------
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=43deg+-3deg
----------
aa=36mm
----------
a=20deg+-5deg b=43deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Stop
(3)Use the hole at R = aa
(4)Set the stop adjuster screw
----------
aa=39mm
----------
a=40deg+-5deg b=23deg+-5deg c=(13.5deg) d=(15deg)+-5deg
----------
aa=39mm
----------
a=40deg+-5deg b=23deg+-5deg c=(13.5deg) d=(15deg)+-5deg
0000001501 LEVER
f1:Direction for pulling the speed lever
f2:Direction for pulling the stop lever
Stop lever's normal position setting method
1. (1) Push in the set bolt (A) until the rack starts to move.
(2)Return the bolt N1 turns from that position and set.
2. Rack with limiter
(1)Return the bolt N1 turns from the rack limit position and set.
----------
N1=1.5
----------
----------
N1=1.5
----------
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=R1(11.8)mm Rb=(R1-0.4)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=59.3+-0.5cm3/1000st Q2=51.9+-1cm3/1000st
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=-
----------
Ra=R1(11.8)mm Rb=(R1-0.4)mm Pa=88.6+-2.7kPa(665+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=59.3+-0.5cm3/1000st Q2=51.9+-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:
The cylinder head is either water-cooled or air-cooled by fins in order to prevent overheating by the compression heat of the air compressor.The water-cooled type has coolant led from the oil cooler to cool cylinder head valves. Coolant is then returned to the rear end of the engine cylinder head.1.2 Pressure Governor
The pressure governor controls compressor operation to keep the air tank pressure within specified limits.To the high pressure valve of the diaphragm, the same air pressure as in the air tank acts always through the filter, thereby balancing with the adjusting spring force. When the pressure in the air tank increases to exceed that opening pressure of the high pressure valve, the air forces up the high pressure valve seat of the diaphragm. This causes increase of acting area so that the diaphragm moves up quickly to close the seat of the low pressure valve.When the low pressure valve is closed, air now flows through the valve body to force down the unloader valve of the air compressor, thereby stopping air supply to the air tank.As the air pressure in the air tank gradually drops, the diaphragm is forced down by the adjusting spring and the low pressure valve opens and the high pressure one closes. As a result, the air on the unloader side is exhausted through the exhaust hole and air supply to the air tank is resumed.2. Specifications
3. Service Standards
3.1 Service Standards Table
(1) Air Compressor (2) Pressure Governor 3.2 Tightening Torque Table
(1) Air compressor (2) Pressure governor 4. Special Tool
5. Service Procedure
5.1 Air Compressor
Removal and installation
The removal and installation procedures of the air compressor are same as those of the pump drive case. See Group 13 Fuel and Engine Control.Disassembly
Disassembly(1) Removal of suction valve holder Using special tool, Air Compressor Suction Valve Tool, remove the suction valve holder.(2) Removal of delivery valve holder (Air-cooled type only) Using special tool, Air Compressor Delivery Valve Tool, remove the delivery valve holder.(3) Removal of piston ring Using special tool, Piston Ring Tool, remove the piston ring.Inspection
Inspection(1) Piston to cylinder liner clearance Calculate the clearance and if it exceeds the limit, replace the piston or cylinder liner.(2) Piston ring to ring groove clearance Measure the clearance and if it exceeds the limit, replace the piston ring or piston. Measure over entire circumference of the piston.(3) Piston ring open end gap Fit the piston ring to a new cylinder liner or gauge and measure the open end gap. If the gap exceeds the limit, replace the ring. Push in the piston ring flat by the piston and measure.(4) Piston to piston pin clearance Calculate the clearance and if it exceeds the limit, replace the piston or piston pin.(5) Piston to connecting rod clearance Calculate the clearance and if it exceeds the limit, replace the piston pin or connecting rod.(6) Crankshaft pin to connecting rod bearing clearance Calculate the clearance and if it exceeds the limit, replace the bearing.(7) Connecting rod end play If the end play exceeds the limit,
The pressure governor controls compressor operation to keep the air tank pressure within specified limits.To the high pressure valve of the diaphragm, the same air pressure as in the air tank acts always through the filter, thereby balancing with the adjusting spring force. When the pressure in the air tank increases to exceed that opening pressure of the high pressure valve, the air forces up the high pressure valve seat of the diaphragm. This causes increase of acting area so that the diaphragm moves up quickly to close the seat of the low pressure valve.When the low pressure valve is closed, air now flows through the valve body to force down the unloader valve of the air compressor, thereby stopping air supply to the air tank.As the air pressure in the air tank gradually drops, the diaphragm is forced down by the adjusting spring and the low pressure valve opens and the high pressure one closes. As a result, the air on the unloader side is exhausted through the exhaust hole and air supply to the air tank is resumed.2. Specifications
3. Service Standards
3.1 Service Standards Table
(1) Air Compressor (2) Pressure Governor 3.2 Tightening Torque Table
(1) Air compressor (2) Pressure governor 4. Special Tool
5. Service Procedure
5.1 Air Compressor
Removal and installation
The removal and installation procedures of the air compressor are same as those of the pump drive case. See Group 13 Fuel and Engine Control.Disassembly
Disassembly(1) Removal of suction valve holder Using special tool, Air Compressor Suction Valve Tool, remove the suction valve holder.(2) Removal of delivery valve holder (Air-cooled type only) Using special tool, Air Compressor Delivery Valve Tool, remove the delivery valve holder.(3) Removal of piston ring Using special tool, Piston Ring Tool, remove the piston ring.Inspection
Inspection(1) Piston to cylinder liner clearance Calculate the clearance and if it exceeds the limit, replace the piston or cylinder liner.(2) Piston ring to ring groove clearance Measure the clearance and if it exceeds the limit, replace the piston ring or piston. Measure over entire circumference of the piston.(3) Piston ring open end gap Fit the piston ring to a new cylinder liner or gauge and measure the open end gap. If the gap exceeds the limit, replace the ring. Push in the piston ring flat by the piston and measure.(4) Piston to piston pin clearance Calculate the clearance and if it exceeds the limit, replace the piston or piston pin.(5) Piston to connecting rod clearance Calculate the clearance and if it exceeds the limit, replace the piston pin or connecting rod.(6) Crankshaft pin to connecting rod bearing clearance Calculate the clearance and if it exceeds the limit, replace the bearing.(7) Connecting rod end play If the end play exceeds the limit,