Information injection-pump assembly
BOSCH
9 400 618 927
9400618927
ZEXEL
107691-2610
1076912610
Rating:
Service parts 107691-2610 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME015202
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-2610
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 927
9400618927
ZEXEL
107691-2610
1076912610
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
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
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
5.1
5.07
5.13
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
Rack position
(9.6)
Vist
V
2.41
2.41
2.41
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
95
94
96
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(5.8)
Vist
V
3
2.9
3.1
Pump speed
r/min
445
445
445
Average injection quantity
mm3/st.
16
14.5
17.5
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
PS407910-303*
V
V1+0.05+
-0.01
PS407910-303*
mm
5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1070--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1020
Advance angle
deg.
0
-0.5
0
Governor adjustment_03
Pump speed
r/min
1080
Advance angle
deg.
-1.3
-1.8
-0.8
Remarks
Finish
Finish
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
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
5.1
5.07
5.13
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
1.95
2.05
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
5.1
5.07
5.13
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=39.5deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=39.5deg+-5deg b=37deg+-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=6deg bb=5.1+-0.03mm
----------
a=(8deg)
----------
aa=6deg bb=5.1+-0.03mm
----------
a=(8deg)
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.
----------
----------
----------
----------
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 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.
----------
----------
----------
----------
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 19 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.
----------
----------
----------
----------
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=1.6V
----------
----------
V1=1.6V
----------
Information:
start by: a) remove valve cover The following steps can be used for the direct injection and precombustion engines except the direct injection engines do not have glow plugs and wires. 1. Remove clip (2) for glow plug wire and fuel injection line (1). Use tool (A) to remove the fuel injection line from the fuel injection valve. 2. Remove fuel line adapters (4) and the spacers from valve cover base (3). Remove the O-ring seal from the adapter.3. Remove bolts (5) and washers (6) that hold rocker shaft assembly (7).4. Remove the rocker shaft assembly. All push rods except those at each end can be removed without removal of the rocker shaft.5. Remove the push rods from the cylinder head.6. Remove intake bridge (9) and exhaust bridge (8) from the bridge dowels. Put identification on the parts to prevent a mix at installation.Install Rocker Shaft Assembly And Push Rods
1. Put clean SAE 30 oil on the bridge dowel and install exhaust bridge (3) and intake bridge (2) in their correct locations.2. Put finger pressure on top of the bridge and turn the adjusting screw clockwise until it makes contact with the valve stem. Turn the adjusting screw 20° to 30° more. Hold the adjusting screw in this position and tighten the locknut to a torque of 22 3 lb.ft. (28 4 N m).3. Put clean SAE 30 oil on top of the pad on the bridge.4. Install push rods (1) and the rocker shaft assembly. Put clean SAE 30 oil on the threads of the bolts that hold the rocker shaft in position. Install the bolts and washers. 5. Tighten the bolts that hold rocker shaft assembly (8) as follows: a) Tighten the bolts in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten the bolts again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten the bolts again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).6. Make an adjustment of the correct valve clearances. The clearance must be .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 7. Put clean SAE 30 oil on the O-ring seal and install O-ring seal (9) on adapter (10). Install the adapter in valve cover base (11). Install the locks, spacers and nuts that hold it.8. Install the fuel injection line on the adapter and the fuel injection valve. Tighten the nut on the fuel injection valve with tool (A) to a torque of 55 5 lb.ft. (75 7 N m). Tighten the nut on the adapter with tool (A) to a torque of 30 5 lb.ft. (40 7 N m).9. Connect the wire to the glow plug. Connect the clip for the glow plug to the fuel injection line with the wire on the same side as the
1. Put clean SAE 30 oil on the bridge dowel and install exhaust bridge (3) and intake bridge (2) in their correct locations.2. Put finger pressure on top of the bridge and turn the adjusting screw clockwise until it makes contact with the valve stem. Turn the adjusting screw 20° to 30° more. Hold the adjusting screw in this position and tighten the locknut to a torque of 22 3 lb.ft. (28 4 N m).3. Put clean SAE 30 oil on top of the pad on the bridge.4. Install push rods (1) and the rocker shaft assembly. Put clean SAE 30 oil on the threads of the bolts that hold the rocker shaft in position. Install the bolts and washers. 5. Tighten the bolts that hold rocker shaft assembly (8) as follows: a) Tighten the bolts in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten the bolts again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten the bolts again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).6. Make an adjustment of the correct valve clearances. The clearance must be .015 in. (0.38 mm) for intake and .030 in. (0.76 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 7. Put clean SAE 30 oil on the O-ring seal and install O-ring seal (9) on adapter (10). Install the adapter in valve cover base (11). Install the locks, spacers and nuts that hold it.8. Install the fuel injection line on the adapter and the fuel injection valve. Tighten the nut on the fuel injection valve with tool (A) to a torque of 55 5 lb.ft. (75 7 N m). Tighten the nut on the adapter with tool (A) to a torque of 30 5 lb.ft. (40 7 N m).9. Connect the wire to the glow plug. Connect the clip for the glow plug to the fuel injection line with the wire on the same side as the