Information injection-pump assembly
BOSCH
9 400 612 848
9400612848
ZEXEL
108622-0091
1086220091
Rating:
Service parts 108622-0091 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-96611
12.
Open Pre:MPa(Kqf/cm2)
18.6{190}/22.6{230}
14.
NOZZLE
Include in #1:
108622-0091
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 848
9400612848
ZEXEL
108622-0091
1086220091
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
134424-4120
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.
407980-2
24*
Digi switch no.
31
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
1-4-2-6-
3-5
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 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
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Rack position
(15.4)
Vist
V
1.54
1.54
1.54
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
176.5
174.5
178.5
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(8.9)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
14.5
13.5
15.5
Max. variation between cylinders
%
0
-10
10
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
4
3.95
4.05
Output voltage
V
2.45
2.44
2.46
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.4
6.37
6.43
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.4
Output voltage
V
3
2.98
3
Confirmation
*
_06
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=20mm
----------
a=20deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=20deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(30deg)
----------
aa=6.4+-0.03mm
----------
a=(30deg)
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 10 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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----------
----------
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Information:
Illustration 5 g06198951
70-Pin connector
(5) Pin 4
(6) Pin 24
Illustration 6 g06198953
40-Pin connector
(7) Pin 4
(8) Pin 24
Using the appropriate terminal extraction tool, remove the red and black wires from positions 4 and 24 of the connector. Refer to Illustration 5 and 6.
Route the extracted wires out of the engine harness and insert the wires into 3E-3370 Connector Receptacle As supplied with 517-0586 Engine Harness As. Red wire in position 1 and Black wire in position 2.Note: Minor cutting of the boot may be required.
Install the Red wire from 517-0586 Engine Harness As into position 4 of the Machine Interface Connector and install the Black wire into position 24 of the connector.
Illustration 7 g06237613
70 Pin Harness
(A) Pin 4 From Machine Interface Harness Connector
(B) Pin 24 From Machine Interface Harness Connector
(C) Pyrometer Harness Interface Connector
(D) Machine Interface Connector
Illustration 8 g06237606
40 Pin Harness
(A) Pin 4 From Machine Interface Harness Connector
(B) Pin 24 From Machine Interface Harness Connector
(E) Flying Power Leads from 514-3813 Harness As to 2 Pin Connector
(F) Machine Interface Connector
If the Pyrometer Interface Harness connector is a 70 pin, Route 517-0586 Engine Harness As to the Pyrometer Harness Interface connector and install Red wire into position 70 and the Black wire into position 69. If the Pyrometer Interface Harness connector is a 40 pin, install the Red wire into pin 1 of a 2-pin receptacle and the Black wire into pin 2. This connector will then connect to G-C3 of 514-3813 Engine Harness As.
With the engine powered, use a digital multimeter to verify that 24V power is present at the Pyrometer Harness Interface connector.Installation of 510-4068 Electronic Control Gp (Pyrometer)
Attach 489-3081 Harness As to 510-4068 Electronic Control Gp (Pyrometer) and the Pyrometer Interface Connector. Using 489-3081 Engine Harness As as a gauge, temporarily install the module on an appropriate place as per the choice of installer.Installation of 505-1731 Engine Harness As
If the engine under test is a 16 cylinder instead of a 20 cylinder, 505-1731 Engine Harness As can be installed between 489-3081 Engine Harness As and 510-4068 Electronic Control Gp.Installation of 489-3081 Engine Harness As
Perform the following procedure to install 489-3081 Engine Harness As:
Install 504-3341 Engine Harness As on the service port connector of 489-3081 Engine Harness As.
Route 504-3341 Engine Harness As to a safe location before performing tests.Note: Attach 140-9442 "Y" Adapter Cable As in order to see all the machine ECMs. Connect 504-3341 Monitor Harness As to "Y", connect other leg to Machine Service port and the third leg to Communication Adapter.Overview and Configuration On Caterpillar Electronic Technician (Cat ET)
This section will describe the overview and configuration setting on Cat ET.Cat ET Screen - Standard View
Perform the following instructions once the system is installed:
Connect to communications adapter and launch Cat ET.
Illustration 9 g06198935
After connecting, under "Available ECM(s)" select "Digital Pyrometer #1".
Illustration 10 g06199349
(9) Status button
Select the "Status" (9) button in the toolbar and then the parameters of "Digital Pyrometer #1" will appear.
Selecting "Engine Cylinder Temperature - 1"