Information injection-pump assembly
BOSCH
9 400 612 877
9400612877
ZEXEL
108622-2220
1086222220
Rating:
Service parts 108622-2220 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
ME151252
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/24.5{250}
14.
NOZZLE
Include in #1:
108622-2220
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 877
9400612877
ZEXEL
108622-2220
1086222220
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
131425-0220
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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.
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
1-5-3-6-
2-4
Pre-stroke
mm
8.5
8.47
8.53
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
12.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
118
116.4
119.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.4+-0.5
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
14
12
16
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
8.4+-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(12.5)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
118
117
119
Basic
*
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
116.5
112.5
120.5
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
0000001601
Pre-stroke
mm
8.5
8.47
8.53
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
6.1
6.05
6.15
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
8.5
8.47
8.53
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
5.5
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:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=AC06
----------
----------
T1=AC06
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=45mm
----------
a=33.5deg+-5deg b=30.5deg+-3deg
----------
aa=45mm
----------
a=33.5deg+-5deg b=30.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.)
(2)Normal engine position (equivalent to R = cc).
(3)Use the hole above R = dd
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=33.5mm
----------
a=41deg+-5deg b=25.5deg+-5deg c=(31deg)
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=33.5mm
----------
a=41deg+-5deg b=25.5deg+-5deg c=(31deg)
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.: aa
(7)Pre-stroke: bb
----------
aa=4deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)
----------
aa=4deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)
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 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.
----------
----------
----------
----------
0000002201 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=8+-0.1mm
----------
----------
N1=325r/min Ra=8+-0.1mm
----------
0000002301 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=1100r/min Ra=R1(12.5)+1mm
----------
----------
N1=1100r/min Ra=R1(12.5)+1mm
----------
Information:
Unit: mm (in.)
Measuring clearance between piston ring and groove(b) If the clearance still exceeds the limit after new piston rings have been installed, replace the piston.(3) Clearance between ends of piston ring Put the piston ring in a gauge or in the bore in a new cylinder block and measure the clearance between the ends of the ring with a feeler gauge as shown in the illustration. If the gauge as shown in the illustration. If the clearance exceeds the limit, replace all the rings.
Measuring clearance between ends of piston ring Put the piston ring in the gauge or cylinder squarely with the piston.
Unit: mm (in.)(4) Clearance between piston pin and piston Measure the diameter of the piston pin and the bore in the piston for the pin as shown in the illustration to find the clearance. If the clearance exceeds the limit, replace the piston or pin whichever is badly worn.
Unit: mm (in.)
Measuring piston pin and bore in piston for pin2. Connecting rods Check the connecting rod for bend or twist as follows:(a) Measure "C" and "l". If "C" exceeds 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) of "l", straighten the connecting rod with a press.
Unit: mm (in.)
Checking connecting rod for bend or twist(b) Generally, a connecting rod aligner is used to check the connecting rod for bend or twist. To check the rod for bend, install the cap to the connecting rod and tighten the cap nuts to the specified torque.
Check connecting rod on a connecting rod aligner(c) To check the connecting rod fitted to the piston for bend, put the connecting rod and piston on the surface plate as shown in the illustration, insert a round bear having a diameter equal to that of the crankpin into the bore in the big end of the rod and measure "A" and "B" with a dial indicator. Subtract "A" from "B" to find the bend ("C").
Checking connecting rod for bend with a dial indicator 3. Crankshaft(1) Clearance between crankpin and connecting rod bearing(a) Install the bearing (upper and lower halves) and cap to the big end of the connecting rod and tighten the cap nuts to the specified torque. Measure the bore in the bearing for crankpin as shown in the illustration. (b) Measure the diameter of the crankpin as shown in the illustration to find the clearance between the crankpin and connecting rod bearing.
Unit: mm (in.)
Measuring diameter of crankpin(c) If the clearance exceeds the limit, install a new bearing and check the clearance again. (d) If the clearance still exceeds the limit, grind the crankpin to 0.25 mm (0.0098 in.), 0.50 mm (0.0197 in.) or 0.75 mm (0.0295 in.) undersize and use undersize connecting rod bearing.Crankpin undersizes
Unit: mm (in.)
a) Grind all the crankpins of one crankshaft to the same undersize.b) Finish the crankpin fillets to a radius of 2.5 mm (0.098 in.).
Crankpin fillet radius(2) Clearance between journal and main bearing (a) Install the main bearing (upper and lower halves) and cap to the cylinder