Information injection-pump assembly
BOSCH
9 400 619 560
9400619560
ZEXEL
106681-4331
1066814331
Rating:
Service parts 106681-4331 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106681-4331
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 560
9400619560
ZEXEL
106681-4331
1066814331
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
131424-7120
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
1-4-2-6-
3-5
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
16.5
Pump speed
r/min
1100
1100
1100
Each cylinder's injection qty
mm3/st.
444
430.7
457.3
Basic
*
Fixing the lever
*
Boost pressure
kPa
120
120
Boost pressure
mmHg
900
900
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.1+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
11
9.3
12.7
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
385
375
395
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
R1-3.2
Boost pressure
kPa
40
37.3
42.7
Boost pressure
mmHg
300
280
320
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(16.5)
Boost pressure
kPa
107
100.3
113.7
Boost pressure
mmHg
800
750
850
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1025
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
K=13 BCL=3.2+-0.1mm
----------
----------
K=13 BCL=3.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(11deg)+-5deg b=(33deg)+-5deg
----------
----------
a=(11deg)+-5deg b=(33deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=(73deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
3. Remove connecting rod caps (1) from the two connecting rods and push the pistons up until the rings are free of the cylinder liner.4. Remove the two pistons.5. Do the above steps again for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the piston rings on the piston until the ring openings (gap) are approximately 180° apart.
Never install tool (A) (the ring compressor) without the use of the cylinder liner as a guide. Damage to the piston rings can be the result.
TYPICAL EXAMPLE4. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into position while the connecting rod is put into position over the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow Steps 1 through 6 for the installation of the other pistons.end by:a) install oil pumpb) install cylinder head assemblyDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove keystone rings from the piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Clean the piston ring grooves on the old piston with an acceptable ring groove tool. For clearances on pistons and rings of earlier models, see PISTON AND RINGS in SPECIFICATIONS.4. See SPECIAL INSTRUCTIONS, Form SMHS7295 for USE OF PISTON PIN REMOVAL AND INSTALLATION TOOLS. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 350°-500°F (176°-260°C). Never use a direct flame to heat a connecting rod. 6. Put the connecting rod in position on tooling (B) for the regular rod. Use tooling (C) for the tapered rod. Put a new rod pin bearing in position. Make sure the rod pin bearing joint (4) is 90° from a center line through crankshaft and pin bearing bores.7. Remove the old rod pin bearing and install the new rod pin bearing with one operation. 8. Use a pin bearing machine
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the piston rings on the piston until the ring openings (gap) are approximately 180° apart.
Never install tool (A) (the ring compressor) without the use of the cylinder liner as a guide. Damage to the piston rings can be the result.
TYPICAL EXAMPLE4. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into position while the connecting rod is put into position over the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow Steps 1 through 6 for the installation of the other pistons.end by:a) install oil pumpb) install cylinder head assemblyDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove keystone rings from the piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Clean the piston ring grooves on the old piston with an acceptable ring groove tool. For clearances on pistons and rings of earlier models, see PISTON AND RINGS in SPECIFICATIONS.4. See SPECIAL INSTRUCTIONS, Form SMHS7295 for USE OF PISTON PIN REMOVAL AND INSTALLATION TOOLS. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 350°-500°F (176°-260°C). Never use a direct flame to heat a connecting rod. 6. Put the connecting rod in position on tooling (B) for the regular rod. Use tooling (C) for the tapered rod. Put a new rod pin bearing in position. Make sure the rod pin bearing joint (4) is 90° from a center line through crankshaft and pin bearing bores.7. Remove the old rod pin bearing and install the new rod pin bearing with one operation. 8. Use a pin bearing machine