Information injection-pump assembly
BOSCH
9 400 611 169
9400611169
ZEXEL
108622-2290
1086222290
Rating:
Service parts 108622-2290 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
ME152421
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
108622-2290
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 169
9400611169
ZEXEL
108622-2290
1086222290
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
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
1-5-3-6-
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
Rack position
(10.3)
Vist
V
2.3
2.3
2.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
115.5
114.5
116.5
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_02
Rack position
(6.9)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
310
310
310
Average injection quantity
mm3/st.
20
18
22
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
8.4+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
8.5
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=3deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=3deg+-5deg b=37deg+-5deg
0000000901
(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=3deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)
----------
aa=3deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)
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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----------
----------
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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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----------
----------
----------
0000001901 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 (154610-0620)
(1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01.
(2)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)
----------
V1=1.6V
----------
----------
V1=1.6V
----------
Information:
Disassembling alternator(2) Removing Pulley(a) Wrap cloth around the rotor, then clamp the rotor in a vise. Remove the pulley nut and then the pulley and spacer.(b) Pull the rotor out of the front bracket.
Removing pulley(3) Removing Stator and Rectifier(a) Unsolder from the rectifier the leads that connect the rectifier to the stator coils. Then, remove the stator.
Unsolder the leads quickly to prevent heat from damaging the diodes.
(b) Remove the rectifier's mounting screws, then remove the rectifier.
Removing stator3.4 Inspection KEY POINTS FOR INSPECTION(1) Inspecting RectifierWith each diode, measure the resistance between the diode terminal and the heat sink. Measure the resistance with the tester's (+) probe applied to the diode terminal and with the tester's (-) probe applied to the diode terminal. If the resistance is infinite in both cases, there is an open circuit. If the resistance is close to zero in both cases, there is a short circuit. An open circuit or short circuit indicates a diode fault. Replace the rectifier if any diode is faulty.Next, measure the resistance between the terminals of the leads that connect the rectifier to the stator coil for each of the diodes. If any measurement reveals an open circuit (infinite resistance) or a short circuit (near-zero resistance), replace the rectifier.
Inspecting rectifier(2) Inspecting Field Coil(a) Check whether continuity exists between the rotor's slip rings. If continuity does not exist, the field coil is open-circuited and the rotor must be replaced.
Field coil continuity test(b) Check whether continuity exists between each slip ring and the rotor shaft (or core). If continuity exists, the field coil is grounded and the rotor must be replaced.
Field coil ground test(3) Inspecting Stator Coils(a) Check whether continuity exists between the leads at the ends of each stator coil. If continuity does not exist between any coil's leads, there is an open circuit and the stator must be replaced.
Stator coil continuity test(b) Check whether continuity exists between each stator coil lead and the stator core. If continuity exists, the stator coil is grounded and the stator must be replaced.
Stator coil ground test(4) Inspecting Brushes(a) Replace the brush if it is worn down to the wear limit line.
Inspecting brush(b) To replace the brush, remove the cover (see the drawing) then unsolder and take out the brush set.
Replacing brush3.5 AssemblyPerform assembly by following the disassembly sequence in reverse. KEY POINTS FOR ASSEMBLY(1) Heat the rear bracket before press-fitting the rear bearing into it. Do not apply oil or grease to the outer or inner surface of the bearing.(2) Before fitting the rotor in the rear bracket, insert a thin metal rod into the small hole in the rear bracket to keep the brushes raised. Remove the metal rod when assembly is complete.
Assembling alternator3.6 InstallationPerform installation by following the removal sequence in reverse. KEY POINTS FOR INSTALLATION Insertion of spacer and clearance adjustmentInstallation of the support bolt is accompanied by insertion of a spacer. Install the spacer as follows:(a) Insert the support bolt into pinion. (Do not install the nut.)(b) Install the alternator