Information injection-pump assembly
BOSCH
9 400 611 672
9400611672
ZEXEL
108622-2311
1086222311
Rating:
Service parts 108622-2311 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}
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
108622-2311
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 672
9400611672
ZEXEL
108622-2311
1086222311
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
131424-8020
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
1-5-3-6-
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.
116.5
115.5
117.5
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
(6.8)
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=19deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=19deg+-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.
----------
----------
----------
----------
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.
----------
----------
----------
----------
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:
When fuel has stopped flowing out, turn the crankshaft slightly in the reverse direction such that fuel flows out. Then, slowly turn the crankshaft clockwise again to more accurately verify the point at which fuel stops flowing out.
End of fuel flow(c) If the IT mark on the crankshaft pulley and the mark on the gear case are aligned when fuel stops flowing out the injection timing is normal.
Timing marks(3) Adjustment
(a) If the injection timing is out of specification, make adjustments by increasing or decreasing the thickness of the injection pump's mounting shim. A change of 0.1 mm in the shim thickness yields a change of approximately 1° in the injection timing.
Injection timing adjusting shim(b) Increasing the shim thickness retards the injection timing, and decreasing the shim thickness advances it. Shims come in 9 different thicknesses from 0.2 mm (0.008 in.) to 1.0 mm (0.039 in.) at intervals of 0.1 mm (0.004 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.
Before using any shim, apply sealant to both sides to prevent oil leakage.
(c) After making adjustments, check the injection timing is correct.(d) Close the cock on the fuel filter, then fit the delivery valve spring and injection pipe in their original positions.
Adjusting injection timingAdjusting Idle Speed
(1) Preparation for Adjustment
(a) Warm up the engine unit the coolant reaches a temperature of 60°C (140°F) or higher.(b) Make sure the valve clearances, injection timing, and injectors are normal.(2) Adjusting Low-Idle Speed
Loosen the locknut on the idling set bolt, turn the bolt to achieve the specified low-idle speed (1000 25min-1), then tighten the lock nut to hold the bolt in that position.(3) Adjusting No-Load Maximum Speed
Loosen the lock nut on the high-speed set bolt, turn the bolt to achieve the specified no-load maximum speed (2600 +30-10 min-1), then tighten the lock nut to hold the bolt in that position.
Adjusting idle speedAdjusting Fan Belt Tension
(1) Press the fan belt with the specified force mid-way between the alternator pulley and crankshaft pulley, and observe the extent of deflection.Unit: mm (in.) (2) If the extent of deflection is out of specification, loosen the adjusting bolt and adjust the fan belt tension by moving the alternator. Retighten the adjusting bolt securely.
Adjusting fan belt tensionRunning in the Engine
After an overhaul, the engine should be tested and inspected on a dynamometer. This operation serves to run in the engine's major moving parts.Starting the Engine
(1) Before starting the engine, check the coolant, engine oil and fuel levels and bleed all air out of the fuel and cooling systems.(2) Without supplying fuel to the engine, crank the engine for about 10 seconds to permit oil to circulate through it.(3) Move the speed control lever slightly in the fuel-increase direction. (Do not move the lever to the full-injection position.) Then, turn the starter switch to the START position to start the engine.(4) Once the engine has started, set it to the low-idle speed using the speed control lever.Inspection after
End of fuel flow(c) If the IT mark on the crankshaft pulley and the mark on the gear case are aligned when fuel stops flowing out the injection timing is normal.
Timing marks(3) Adjustment
(a) If the injection timing is out of specification, make adjustments by increasing or decreasing the thickness of the injection pump's mounting shim. A change of 0.1 mm in the shim thickness yields a change of approximately 1° in the injection timing.
Injection timing adjusting shim(b) Increasing the shim thickness retards the injection timing, and decreasing the shim thickness advances it. Shims come in 9 different thicknesses from 0.2 mm (0.008 in.) to 1.0 mm (0.039 in.) at intervals of 0.1 mm (0.004 in.). The thickness is not indicated on the shim, so any shim should be measured with a vernier caliper before being used.
Before using any shim, apply sealant to both sides to prevent oil leakage.
(c) After making adjustments, check the injection timing is correct.(d) Close the cock on the fuel filter, then fit the delivery valve spring and injection pipe in their original positions.
Adjusting injection timingAdjusting Idle Speed
(1) Preparation for Adjustment
(a) Warm up the engine unit the coolant reaches a temperature of 60°C (140°F) or higher.(b) Make sure the valve clearances, injection timing, and injectors are normal.(2) Adjusting Low-Idle Speed
Loosen the locknut on the idling set bolt, turn the bolt to achieve the specified low-idle speed (1000 25min-1), then tighten the lock nut to hold the bolt in that position.(3) Adjusting No-Load Maximum Speed
Loosen the lock nut on the high-speed set bolt, turn the bolt to achieve the specified no-load maximum speed (2600 +30-10 min-1), then tighten the lock nut to hold the bolt in that position.
Adjusting idle speedAdjusting Fan Belt Tension
(1) Press the fan belt with the specified force mid-way between the alternator pulley and crankshaft pulley, and observe the extent of deflection.Unit: mm (in.) (2) If the extent of deflection is out of specification, loosen the adjusting bolt and adjust the fan belt tension by moving the alternator. Retighten the adjusting bolt securely.
Adjusting fan belt tensionRunning in the Engine
After an overhaul, the engine should be tested and inspected on a dynamometer. This operation serves to run in the engine's major moving parts.Starting the Engine
(1) Before starting the engine, check the coolant, engine oil and fuel levels and bleed all air out of the fuel and cooling systems.(2) Without supplying fuel to the engine, crank the engine for about 10 seconds to permit oil to circulate through it.(3) Move the speed control lever slightly in the fuel-increase direction. (Do not move the lever to the full-injection position.) Then, turn the starter switch to the START position to start the engine.(4) Once the engine has started, set it to the low-idle speed using the speed control lever.Inspection after