Information injection-pump assembly
BOSCH
9 400 612 403
9400612403
ZEXEL
107492-2100
1074922100
Rating:
Service parts 107492-2100 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME015202
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107492-2100
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 403
9400612403
ZEXEL
107492-2100
1074922100
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0520
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
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
02
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
01
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
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
101
99.4
102.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.4+-0.5
Pump speed
r/min
540
540
540
Average injection quantity
mm3/st.
16
14.5
17.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5.5+-0.0
3
PS407910-303*
V
V1+0.05+
-0.01
PS407910-303*
mm
5.5+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
101
100
102
Fixing the lever
*
Boost pressure
kPa
42
42
Boost pressure
mmHg
315
315
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.55
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
99
95
103
Fixing the lever
*
Boost pressure
kPa
42
42
Boost pressure
mmHg
315
315
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-0.75
Boost pressure
kPa
22
20.7
23.3
Boost pressure
mmHg
165
155
175
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
95)
Boost pressure
kPa
28.7
28.7
28.7
Boost pressure
mmHg
215
215
215
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
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)Boost compensator stroke: BCL
----------
T1=K79 BCL=0.75+-0.1mm
----------
----------
T1=K79 BCL=0.75+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=22deg+-5deg b=(38deg)+-3deg
----------
----------
a=22deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper screw so that speed = bb and the rack position = cc and confirm non-injection.
(3)After setting the stopper bolt, confirm non-injection at speed dd.
----------
aa=40mm bb=1450r/min cc=1-0.5mm dd=400r/min
----------
a=36.5deg+-5deg b=(45deg)+-5deg
----------
aa=40mm bb=1450r/min cc=1-0.5mm dd=400r/min
----------
a=36.5deg+-5deg b=(45deg)+-5deg
0000001301
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1500r/min Ra=R1(11.8)+1.55mm
----------
----------
N1=1500r/min Ra=R1(11.8)+1.55mm
----------
Information:
Crankshaft Turns Free Exhaust Smoke Can Be Seen While Starting
Cold Outside Temperatures ... It may be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10°F (-12°C).Air in Fuel System ... See PRIMING THE FUEL SYSTEM.Low Quality Fuel ... Drain a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, drain the tank and fill with a good quality fuel. Change the fuel filter and "prime". If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.Fuel Injection Timing Not Correct. *Valve Adjustment Not Correct ... Check and make necessary adjustment. See VALVE LASH ADJUSTMENT.Defective Fuel Nozzle(s) ... Replace the fuel nozzles.Low Compression ... See the topic MISFIRING AND RUNNING ROUGH.Exhaust Smoke Cannot Be Seen While Starting
No Fuel in Tank ... Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.No Fuel From Fuel Injection Pump ... Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, see the following information.Prime fuel system.Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts (terminal voltage while cranking). If voltage is less than 8 volts, the problem is low charge in battery or defective wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the transfer pump is more than the fuel pressure at the fuel filter outlet, install a new fuel filter.Check for a defective fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter
Cold Outside Temperatures ... It may be necessary to use starting aids, or warm engine oil or coolant, at temperatures below 10°F (-12°C).Air in Fuel System ... See PRIMING THE FUEL SYSTEM.Low Quality Fuel ... Drain a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, drain the tank and fill with a good quality fuel. Change the fuel filter and "prime". If there is no water in the fuel, using an outside supply of fuel, prime and start the engine. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel and prime the fuel system.Fuel Injection Timing Not Correct. *Valve Adjustment Not Correct ... Check and make necessary adjustment. See VALVE LASH ADJUSTMENT.Defective Fuel Nozzle(s) ... Replace the fuel nozzles.Low Compression ... See the topic MISFIRING AND RUNNING ROUGH.Exhaust Smoke Cannot Be Seen While Starting
No Fuel in Tank ... Check fuel level visually (do not use the fuel gauge only). Be sure tank selection valve is open to the tank with fuel in it. Be sure valve in fuel line between the tanks is open.No Fuel From Fuel Injection Pump ... Loosen one or more of the fuel injection line nuts at the cylinder heads. With ignition switch on and accelerator in the fuel on position, turn the engine with the starter to be sure there is no fuel from the fuel injection pump. To find the cause for no fuel, see the following information.Prime fuel system.Check solenoid by turning on ignition switch. You must hear a sound when the plunger opens. If no sound is heard, make sure there is battery voltage at the solenoid and that the voltage is no less than 8 volts (terminal voltage while cranking). If voltage is less than 8 volts, the problem is low charge in battery or defective wiring. If voltage is 8 or more volts, loosen the cap on the tee at the fuel filter and release the fuel pressure at the solenoid. If the solenoid now works, the fuel transfer pump is holding fuel pressure at the solenoid. Clean or install a new fuel transfer pump. If solenoid does not work when pressure is released, install a new solenoid.Check for a dirty fuel filter by checking fuel pressure at the fuel filter outlet while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2) check fuel pressure at the outlet of the fuel transfer pump. If fuel pressure at the outlet of the transfer pump is more than the fuel pressure at the fuel filter outlet, install a new fuel filter.Check for a defective fuel transfer pump by checking fuel pressure at the outlet of the fuel transfer pump while turning the engine with the starter. If fuel pressure is less than 13 psi (0,9 kg/cm2), clean the primary fuel filter