Information injection-pump assembly
BOSCH
9 400 619 538
9400619538
ZEXEL
107692-1161
1076921161
ISUZU
8943954950
8943954950
Rating:
Service parts 107692-1161 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
8-94394-606-6
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
107692-1161
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 538
9400619538
ZEXEL
107692-1161
1076921161
ISUZU
8943954950
8943954950
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.
00
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
11
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
1.9
1.87
1.93
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
Adjusting point
-
Rack position
13.3
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102.5
100.9
104.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
5
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.1+-0.5
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
18.5
16.7
20.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
PS407980-224*
V
V1-0.05+
-0.01
PS407980-224*
mm
4.9+-0.0
3
PS407910-303*
V
V1-0.05+
-0.01
PS407910-303*
mm
4.9+-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(13.3)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102.5
101.5
103.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
5
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
5
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-1.9
Boost pressure
kPa
17.3
16
18.6
Boost pressure
mmHg
130
120
140
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
35)
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
0000001601
CU407980-224*
*
Actuator advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
1.9
1.87
1.93
Output voltage
V
1.2
1
1.4
Confirmation
*
_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 advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
1.9
1.87
1.93
Output voltage
V
1.2
1
1.4
Confirmation
*
_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=AB48 BCL=1.9+-0.1mm
----------
----------
T1=AB48 BCL=1.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the pin at R = aa
----------
aa=35mm
----------
a=2deg+-5deg b=32deg+-3deg
----------
aa=35mm
----------
a=2deg+-5deg b=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(3)Use the pin above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
0000001301
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=22deg bb=1.9+-0.03mm
----------
a=(60deg)
----------
aa=22deg bb=1.9+-0.03mm
----------
a=(60deg)
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 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.
----------
----------
----------
----------
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=1250r/min Ra=R1(13.3)+2.35mm
----------
----------
N1=1250r/min Ra=R1(13.3)+2.35mm
----------
Information:
Be sure to read the correct side of the dipstick. The ADD and FULL levels are not the same when checking the oil while stopped or while idling.
Checking Oil Pressure
Immediately after starting, and frequently during operation, observe the oil pressure gauge reading. The indicator should register in the NORMAL range. If the indicator fluctuates or registers below NORMAL range:1. Move the governor control to low idle position.2. Check the oil level. Be sure to read the ENGINE IDLING side of the dipstick.3. Add oil until the oil level is at the FULL mark on the ENGINE IDLING side of the dipstick. Do not overfill.4. Check for oil leaks.5. If necessary, stop the engine and have repairs made.Draining Engine Oil
With engine stopped and oil warm:1. Remove the crankcase oil drain plug.2. Allow the oil to drain. 3. Clean and install the drain plug.OR, if a sump pump is used:1. Connect a suitable drain line and container to the pump outlet.2. With engine stopped and oil warm, open the sump pump valve to the engine crankcase drain line: The two marks on the valve must be turned so that one mark points to the pump, and the second mark points to the engine drain line.3. Operate the sump pump handle until the crankcase is empty.4. Close the valve to the engine crankcase drain line.Cleaning the Breather
1. Release the hose clamp and disconnect the fumes disposal tube.2. Remove the breather assembly. 3. Wash the breather in solvent.4. Allow to drain dry and then wipe.5. Inspect the gasket. Install a new gasket if necessary.6. Install the breather.7. Connect the fumes disposal tube. Changing Oil Filter
1. Unscrew and remove the filter. 2. Be sure the old filter gasket did not remain attached inside the filter base: Leaking will occur between the new filter gasket and this old gasket.3. Wipe the filter base. 4. Apply a thin coat of clean oil to the gasket of the new filter. 5. Install the new filter: Hand tighten the filter 3/4turn after the filter gasket contacts the base. Use rotation index numbers, which are painted on the filter can, as a guide for proper tightening. Filling the Crankcase
1. Fill the crankcase to the safe starting range on the ENGINE STOPPED side of the dipstick. See the Lubrication Specifications for refill capacity and proper oil viscosity. 2. Start the engine and check for oil leaks.3. After the engine is warm, check the oil level with the engine idling.4. Add oil if necessary to maintain the oil level at the FULL mark on the ENGINE IDLING side of the dipstick.Fan Drive Bearings
Lubricate the fan drive bearings with lubricating grease through one fitting, 1 or 2 strokes.
LOCATION OF 4B4550 PRESSURE RELIEF FITTING AND 2D4867 FITTING SHOWN IN THE STANDARD LOCATION.If the grease fitting is not readily accessible, it may be necessary to1. Remove the 4B4550 Fitting (relief) from the fan mounting bracket assembly and install the 2D4867 Fitting in its place.2. Install the 4B4550 Fitting (relief) in place of the