Information injection-pump assembly
BOSCH
9 400 619 891
9400619891
ZEXEL
108622-1040
1086221040
ISUZU
1156032400
1156032400
Rating:
Service parts 108622-1040 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
1-15300-339-2
12.
Open Pre:MPa(Kqf/cm2)
20.1
15.
NOZZLE SET
Include in #1:
108622-1040
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 891
9400619891
ZEXEL
108622-1040
1086221040
ISUZU
1156032400
1156032400
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
131424-7120
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.
33
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
8
7.97
8.03
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
(14)
Vist
V
1.75
1.75
1.75
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
194.5
192.5
196.5
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
5.6+-0.0
5
Injection quantity adjustment_02
Rack position
(6.8)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
380
380
380
Average injection quantity
mm3/st.
20
16.8
23.2
Max. variation between cylinders
%
0
-13
13
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
7.9+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
8
7.97
8.03
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
11.5
11
12
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
2.95
2.94
2.96
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
8
7.97
8.03
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
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=17deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=17deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=0deg bb=8+-0.03mm
----------
a=(100deg)
----------
aa=0deg bb=8+-0.03mm
----------
a=(100deg)
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.
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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 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.
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Information:
Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Required Parts
The LFI component PMMA surface characteristics are as follows
Cover Layer
Gloss
Scratch resistance
Weather resistance
Color Layer
Coloring
Ultraviolet resistance
Carrier Layer
Adhesion to backing foam
Heat deformation resistance
Backing Foam
Strength
Stability
Impact resistance
Heat deformation resistanceRepair Procedure
Illustration 1 g06509785
Simulated punch hole
Illustration 2 g06509787
Location to grind off backside
Grind material off from backside
Illustration 3 g06509788
Fiberglass mat and plastic filler
Place fiberglass mat and place plastic filler on backside
Illustration 4 g06509791
Location to grind off exterior side
Grind material off from exterior side
Illustration 5 g06509792
Location to add filler on exterior side
Fill hole on exterior side with plastic filler
Illustration 6 g06510059
Exterior surface to grind flat
Grind plastic filler on exterior to achieve flat surface
Illustration 7 g06510075
Area to apply plasticiser
Apply plastic filler with plasticiser to the exterior
Illustration 8 g06510079
Exterior area to grind plastic filler containing plasticiser
Grind plastic filler containing plasticiser and also area to be painted
Illustration 9 g06510084
Exterior plastic surface painted with primer
Paint exterior with primer for plastic surfaces
Illustration 10 g06510086
Exterior plastic surface painted with top coat
Paint exterior with top coat