Information injection-pump assembly
BOSCH
9 400 618 915
9400618915
ZEXEL
107691-2481
1076912481
Rating:
Service parts 107691-2481 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-2481
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 915
9400618915
ZEXEL
107691-2481
1076912481
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.
01
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
15
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
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.4
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
87.5
85.9
89.1
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
7.3+-0.5
Pump speed
r/min
530
530
530
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(10.4)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
87.5
86.5
88.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
24.7
24.7
Boost pressure
mmHg
185
185
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+1.4
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
98.5
94.5
102.5
Fixing the lever
*
Boost pressure
kPa
24.7
24.7
Boost pressure
mmHg
185
185
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
500
500
500
Rack position
R2-0.2
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-1.
15)
Boost pressure
kPa
11.3
11.3
11.3
Boost pressure
mmHg
85
85
85
Timer adjustment
Pump speed
r/min
1070--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1020
Advance angle
deg.
0
-0.5
0
Timer adjustment_03
Pump speed
r/min
1080
Advance angle
deg.
-1.3
-1.8
-0.8
Remarks
Finish
Finish
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=L83 BCL=0.2+-0.1mm
----------
----------
T1=L83 BCL=0.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=25deg+-5deg b=(39deg)+-3deg
----------
----------
a=25deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)At speed = bb and rack position = cc, confirm that the stopper bolt is set at the non-injection position.
(3)After setting the stopper bolt, confirm non-injection at speed dd.
----------
aa=40mm bb=1850r/min cc=1-0.5mm dd=365r/min
----------
a=15deg+-5deg b=(45deg)+-5deg
----------
aa=40mm bb=1850r/min cc=1-0.5mm dd=365r/min
----------
a=15deg+-5deg b=(45deg)+-5deg
0000001301
(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)Pre-stroke: bb
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(8deg)
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(8deg)
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 clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in a counter clockwise direction when viewed from the drive side and adjust so that the adjustment point becomes the adjustment value, then fully tighten.
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 SPEED SENSOR
(A) Flyweight projection
(B) Pickup sensor
(c) Lock nut
Speed sensor installation
(1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L.
(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------
----------
L=0.8~1mm
----------
0000002301 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=1450r/min Ra=R1(10.4)+1.4mm
----------
----------
N1=1450r/min Ra=R1(10.4)+1.4mm
----------
Information:
(1) Install pin to get a dimension of ... 4.78 0.25 mm (.188 .010 in.)(2) Install dowel to get a dimension of ... 12.19 0.25 mm (.480 .010 in.)(3) Rack bearing alignment. The center of the rack bearing tab must be within 0.05 mm (.002 in.) of a vertical line that: (a) goes through the center of the rack bearing(b) is parallel to the vertical centerline of injection pump housing The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and 5P6218 Driver.The correct bearing depth [19.0 0.5 mm (.75 .02 in.)] is controlled when driver is stopped by fixture.(4) Position of camshaft bearing joints (X) must be limited to area (A) ... 30 1° When viewed from the Front of the injection pump housing, all three camshaft bearings must be installed with the bearing joint (X) in an area (A) between a vertical position and a position 30° to the Right of vertical. At the same time, oil hole (Y) in the two end bearings (center bearing has no oil hole) must be to the Left of vertical.(5) Distance from bottom of housing to end of rear hollow dowel ... 1.5 0.3 mm (.06 .01 in.)(6) Maximum distance from bottom of housing to end of front hollow dowel ... 1.0 mm (.04 in.)(7) Torque for bolts ... 55 7 N m (40 5 lb.ft.)(8) Distance from rear bearing bore face to installed rear camshaft bearing ... 4.8 0.5 mm (.19 .02 in.)(9) Distance from front bearing bore face to installed front camshaft bearing ... 1.0 0.5 mm (.04 .02 in.) (10) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 0.5 mm (1.12 .02 in.)(11) Install top governor drive bearing (notch end up) with sharp corner even with top surface of housing. Position center of notch so that it is in alignment with the center of oil pressure relief hole (Z) by an amount of ... 10°(12) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel holes with aluminum ball) ... 14.76 0.10 mm (.581 .004 in.)(13) Distance from end of bearing to face of boss on housing ... 73.03 0.51 mm (2.875 .020 in.)(14) Distance between the bearings for the shaft ... 34.80 0.51 mm (1.370 .020 in.)(15) Install pins until they contact bottom of housing casting.