Information injection-pump assembly
BOSCH
9 400 618 924
9400618924
ZEXEL
107691-2580
1076912580
MITSUBISHI
ME072928
me072928
Rating:
Cross reference number
BOSCH
9 400 618 924
9400618924
ZEXEL
107691-2580
1076912580
MITSUBISHI
ME072928
me072928
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
131424-8420
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
17
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
5.6
5.57
5.63
Beginning of injection position
Governor side NO.1
Governor 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
Rack position
(11)
Vist
V
1.8
1.8
1.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
120.5
119.5
121.5
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_02
Rack position
(6)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
15.5
13.7
17.3
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5.5+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
1470
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
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
24
23.5
24.5
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
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
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aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
0000000901
(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=5deg bb=5.6+-0.03mm
----------
a=(0deg)
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(0deg)
Stop lever angle
(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.
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0000001301
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001401
C:Shim
----------
----------
----------
----------
0000001501
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 the counterclockwise 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.
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0000001701
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 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 (154610-0620)
(1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01.
(2)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)
----------
V1=1V
----------
----------
V1=1V
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Information:
start by:a) remove automatic timing advanceb) remove vibration damper and pulleyc) remove water pumpd) remove belt tightener idler pulleye) remove water temperature regulator (left cylinder head)1. Remove the tube assembly from the oil cooler elbow to the oil pan.2. Loosen the bolts that hold the oil pan to the cylinder block approximately 1/4" (6.4 mm). Remove the bolts that hold the oil pan to the timing gear cover.3. Fasten a hoist to the engine and lift it off tool (A). Weight of the engine is 3200 lb. (1452 kg). Make a separation of the oil pan from the cylinder block and timing gear cover. Do not damage the pan gasket.4. Put 1/4" (6.4 mm) pieces of bar stock between the pan and cylinder block at the positions the oil pan makes contact with tool (A). Lower the engine on tool (A).5. Remove the bolts from the belt tightener bracket. Remove the block and gasket. 6. Remove fumes disposal tube (1).7. Remove the bolts (4) that hold the timing gear cover to the cylinder block.8. Remove water bonnet (2).9. Remove timing gear cover (3).
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance