Information injection-pump assembly
BOSCH
9 400 612 392
9400612392
ZEXEL
108622-2313
1086222313
Rating:
Service parts 108622-2313 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:
108622-2313
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 392
9400612392
ZEXEL
108622-2313
1086222313
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.
109
108
110
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
(7.1)
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.
----------
----------
----------
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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 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.
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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:
Installing main bearings(b) Fit the flanged main bearing in the No. 3 journal position.(c) Smear a little engine oil on the inner surface of each bearing.
Installing flanged main bearingInstalling Crankshaft
(a) Wash the crankshaft thoroughly in cleaning solvent, then dry it with compressed air.(b) Keeping the crankshaft horizontal, gently lower it into the cylinder block.(c) Smear a little engine oil on each crankshaft journal.
Installing crankshaftInstalling Main Bearing Caps
(a) Before installing the main bearing caps, apply sealant to the mating surfaces of the frontmost and rearmost caps and to the corresponding surfaces in the cylinder block.
Installing main bearing caps(b) Referring to the cap numbers, fit the main bearing caps sequentially starting at the front of the engine. The arrow on each cap must point toward the front of the engine.
Front marks and cap numbers
Make sure the frontmost and rearmost caps fit flush against the cylinder block.
(4) Tightening Bearing Cap Bolts
Tighten the bearing cap bolts alternately a little at a time, then torque each bolt to specification.
Tightening bearing cap bolts(5) Checking Crankshaft Rotation
Confirm that the crankshaft turns smoothly.
Checking crankshaft rotation(6) Measuring End Plan of Crankshaft
Apply a dial gauge to the end of the crankshaft and measure the end play. If the measurement exceeds the specified limit, replace the No. 3 flanged bearing.
Measuring end play of crankshaft(7) Inserting Side Seals
(a) Apply sealant to the mating surfaces of each side seal. (b) With the radius of each side seal facing the outside, push the side seals part-way into the frontmost and rearmost caps by hand.
Alignment of side seals for installation(c) Press each side seal completely into position using a flat implement. Be careful not to bend the side seals.
Inserting side seals(8) Preparation for Installation of Piston and Connecting Rod Assemblies
(a) Clean each cylinder's inner surface with a rag, then smear each with engine oil.(b) Press the connecting rod bearings (upper and lower) into the connecting rods and caps such that the bearings' lugs fir into the grooves.(c) Smear the connecting rod bearings with engine oil.(d) Turn the cylinder block onto its side.
Preparation for installation of piston and connecting rod assemblies(9) Installing Piston and Connecting Rod Assemblies
(a) Smear the pistons' sliding surfaces and piston rings with engine oil(b) Position the piston ring gaps as shown in the illustration. Do not align any ring gap with the piston pin or at 90° to the piston pin.
Piston ring positions(c) Turn the crankshaft until the crank pin onto which the connecting rod is to be fitted reaches its TDC position.(d) Align the piston such that its front mark (this is stamped on the piston crown) points toward the timing gear case mounting surface (the front of the engine).(e) Using a piston guide (commercially available), insert the piston and connecting rod assembly into the cylinder from the top of the cylinder block.
Inserting piston and connecting rod assembly
If the piston is tapped hard while being inserted, the piston rings may break and the crank pin may become damaged.
(10) Installing Connecting Rod Caps
(a) When the connecting rod's big end is