Information injection-pump assembly
BOSCH
9 400 617 496
9400617496
ZEXEL
106681-4176
1066814176
Rating:
Service parts 106681-4176 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
35A6100010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106681-4176
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 617 496
9400617496
ZEXEL
106681-4176
1066814176
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
Beginning of injection position
Governor side NO.1
Governor 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
11.2
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
303
294
312
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
117
117
Boost pressure
mmHg
875
875
Remarks
Injection at all cylinders.
Injection at all cylinders.
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.6+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
26
23
29
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Injection only at cylinders 1, 3, 4 and 6.
Injection only at cylinders 1, 3, 4 and 6.
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
260
260
280
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-2.5
Boost pressure
kPa
58.7
52
65.4
Boost pressure
mmHg
440
390
490
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(11.2)
Boost pressure
kPa
107
104.3
109.7
Boost pressure
mmHg
805
785
825
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
700
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Idle sub spring setting: L1.
----------
K=25 BCL=2.5+-0.1mm L1=2.5-0.5mm
----------
----------
K=25 BCL=2.5+-0.1mm L1=2.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(20deg)+-5deg b=(29deg)+-5deg
----------
----------
a=(20deg)+-5deg b=(29deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Seal at delivery.
----------
aa=0r/min bb=3-0.5mm
----------
a=27deg+-5deg b=62.5deg+-5deg
----------
aa=0r/min bb=3-0.5mm
----------
a=27deg+-5deg b=62.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
start by:a) remove vibration damper and pulley
The crankshaft front seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made.
1. Make at least three holes in seal (1) with a hammer and a sharp punch. 2. Use tool (A) to remove seal (1). 3. Install tool (C) into the seal bore.4. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.5. Remove tool (C) and the wear sleeve by hand.Install Crankshaft Front Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the front crankshaft seal and wear sleeve with tooling (A). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.
TYPICAL EXAMPLEb. Install locator (3) and bolts (4) on the crankshaft.c. Seal (1) and wear sleeve (2) must be installed dry.
Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (1) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until the inside surface of installer (5) comes in contact with locator (3).h. Remove tooling (A) from the crankshaft seal and wear sleeve. Tooling (A) will install the seal and wear sleeve to the correct depth on the crankshaft.end by:a) install vibration damper and pulley
The crankshaft front seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made.
1. Make at least three holes in seal (1) with a hammer and a sharp punch. 2. Use tool (A) to remove seal (1). 3. Install tool (C) into the seal bore.4. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.5. Remove tool (C) and the wear sleeve by hand.Install Crankshaft Front Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the front crankshaft seal and wear sleeve with tooling (A). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.
TYPICAL EXAMPLEb. Install locator (3) and bolts (4) on the crankshaft.c. Seal (1) and wear sleeve (2) must be installed dry.
Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (1) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until the inside surface of installer (5) comes in contact with locator (3).h. Remove tooling (A) from the crankshaft seal and wear sleeve. Tooling (A) will install the seal and wear sleeve to the correct depth on the crankshaft.end by:a) install vibration damper and pulley