Information injection-pump assembly
BOSCH
9 400 611 183
9400611183
ZEXEL
108622-1171
1086221171
ISUZU
1156033061
1156033061
Rating:
Service parts 108622-1171 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
1-15300-371-4
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/22.1{225}
13.
NOZZLE-HOLDER
14.
NOZZLE
Include in #1:
108622-1171
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 183
9400611183
ZEXEL
108622-1171
1086221171
ISUZU
1156033061
1156033061
Zexel num
Bosch num
Firm num
Name
9 400 611 183
1156033061 ISUZU
INJECTION-PUMP ASSEMBLY
6WG1-TCN * K 14CP TICS HD-TI6F TICS
6WG1-TCN * K 14CP TICS HD-TI6F TICS
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SEJ967d}
1404 Test oil ISO4113 or {SEJ967d}
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
134424-4320
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
RED4 control unit part number
407915-0
590
RED4 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
7
6.97
7.03
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
(14.9)
PWM
%
71.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
222
220
224
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.6+-0.0
5
Injection quantity adjustment_02
Rack position
(6.9)
PWM
%
26.9+-2.
8
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
15
11.8
18.2
Max. variation between cylinders
%
0
-13
13
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.9+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
7
6.97
7.03
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
3
2.95
3.05
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
7
6.97
7.03
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=4deg bb=7+-0.03mm
----------
a=(100deg)
----------
aa=4deg bb=7+-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.
----------
----------
----------
----------
0000001701
(PWM) Pulse width modulation (%)
(R) Rack position (mm)
Rack sensor output characteristics
1. Rack limit adjustment
(1)Measure the rack position R2 for PWM a2%.
(2)Confirm that it is within the range R2 = 15+-1 mm.
(3)Measure the rack position R1 at PWM a %.
(4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm.
2. Check the limp home operation.
(1)Move the switch box's limp home switch to the limp home side.
(2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table.
3. Check the pull down operation.
(1)Confirm that the rack position is 19 mm at PWM B%.
(2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------
Information:
Operations that may cause product damage are identified by notice labels in this publication.
Introduction
This Tool Operating Manual contains two filter installation procedures. This first procedure is for installing a primary filter system. This is a coarse filter and will protect the transfer pump from contamination in the oil. The second procedure outlines installing a secondary filter which is designed to protect injection pumps from contaminated oil. Fuel injection pumps used on the 3208 Engine are one example of a fuel injection pump that requires the secondary filter installation.It will be the dealer choice as to which optional filter is installed on the test stand. Determine what type of filtering will be required most often, and install the appropriate type of filtering system. These filters can only be added to the 15 horsepower test stands.Secondary Filter
Nomenclature
Illustration 1. Nomenclature for Secondary Filter Installation. Refer to Chart A for item identification. Fabricated Parts
All the parts required for this installation can be ordered from Caterpillar Parts Distribution, except bracket (1). This must be manufactured by the bench owner, using the dimensions provided below.This bracket can be made from common SAE1018 steel. Weld the two pieces together.
Illustration 2. Filter Mounting Bracket. Refer to Chart B for dimensions. Installation
Assemble the Fuel Filter
1. Install 053-0088 Fitting (17) with 3J-1907 Seal (18) into the inlet port (left side) of the filter base. (This converts a number 6 STOP port to NPT). Install 5P-4455 Fitting (19) into fitting (17).2. Install 2R-6806 Fitting (15) with 3J-1907 Seal (16) into the outlet port (right side) of the filter base.3. Install 6N-4414 Cover (7) onto the filter base using 1P-0436 Gasket (8), 4B-3388/6V-2317 (9), and OS-1616/6V-8490 Bolt (10).4. Install 9S-4182 Plug (5) with 6V-5084 O-ring Seal (6) into the top of the filter base.5. Install the filter base assembly onto filter bracket (1),