Information injection-pump assembly
BOSCH
9 400 613 296
9400613296
ZEXEL
101608-6530
1016086530
Rating:
Service parts 101608-6530 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME442004
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 296
9400613296
ZEXEL
101608-6530
1016086530
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
131424-8520
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.3
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
128.5
127.5
129.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
525
525
525
Average injection quantity
mm3/st.
8.5
7.2
9.8
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.
Injection quantity adjustment_03
Adjusting point
E
Rack position
10.5++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
3.5
3
4
Timer adjustment_02
Pump speed
r/min
690+-25
Advance angle
deg.
3.5
3
4
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
785+-25
Advance angle
deg.
0
0
0
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
----------
K=6 N1=1050r/min N2=400r/min
----------
----------
K=6 N1=1050r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Fix at stop position at shipping.
----------
----------
a=2deg+-5deg b=31deg+-3deg c=17deg+-5deg
----------
----------
a=2deg+-5deg b=31deg+-3deg c=17deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Rack position = aa, speed = bb (stamp at delivery)
(3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=9deg
----------
a=(7deg)
----------
aa=9deg
----------
a=(7deg)
Information:
Installation of Oil Seal Case (Option)
(1) Coat the outside surface of the oil seal with engine oil.(2) Install the oil seal on the oil seal case.(3) Coat the lip of the oil seal with engine oil.(4) Install the O-ring into the oil seal case, and install the oil seal case on the flywheel housing. The oil seal case must be installed with the "Q" mark facing up.(5) Secure the oil seal case with the bolts.
Installation of oil seal case (option)Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder headTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) Tighten the rocker shaft
(1) Coat the outside surface of the oil seal with engine oil.(2) Install the oil seal on the oil seal case.(3) Coat the lip of the oil seal with engine oil.(4) Install the O-ring into the oil seal case, and install the oil seal case on the flywheel housing. The oil seal case must be installed with the "Q" mark facing up.(5) Secure the oil seal case with the bolts.
Installation of oil seal case (option)Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder headTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) Tighten the rocker shaft