Information injection-pump assembly
BOSCH
9 400 612 893
9400612893
ZEXEL
108622-3090
1086223090
HINO
220007552A
220007552a
Rating:
Service parts 108622-3090 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2391B
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/27.5{280}
14.
NOZZLE
Include in #1:
108622-3090
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 893
9400612893
ZEXEL
108622-3090
1086223090
HINO
220007552A
220007552a
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
21
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
1-4-2-6-
3-5
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 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
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
185.7
183.7
187.7
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.7
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
160.9
157.9
163.9
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.3+-0.1
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
125.9
122.9
128.9
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_04
Adjusting point
D
Rack position
10.6+-0.
1
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
192
182
202
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
Rack limit
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_05
Adjusting point
E
Rack position
4+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12.5
9.5
15.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
7.9
Boost pressure
kPa
22
20
22
Boost pressure
mmHg
165
150
165
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
10.2
Boost pressure
kPa
49.3
49.3
49.3
Boost pressure
mmHg
370
370
370
0000001601
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
5
4.5
5.5
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
4
3.95
4.05
Output voltage
V
2.62
2.61
2.63
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.4
6.37
6.43
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
3.4
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)Tolerance for racks not indicated: +-0.05mm.
(2)Stop lever setting: R1
(3)RACK LIMIT: RAL
(4)Boost compensator stroke: BCL
(5)Damper spring setting
----------
R1=12.4+0.2mm RAL=10.6+-0.1mm BCL=2.3+-0.1mm
----------
----------
R1=12.4+0.2mm RAL=10.6+-0.1mm BCL=2.3+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=11deg+-5deg
----------
----------
a=11deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=50mm
----------
a=25deg+-5deg b=37deg+-3deg
----------
aa=50mm
----------
a=25deg+-5deg b=37deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set stopper screw so that rack position = bb (after setting apply red paint).
(3)Set before governor adjustment.
----------
aa=33mm bb=12.4+0.2mm
----------
a=30deg+-5deg b=42deg+-5deg
----------
aa=33mm bb=12.4+0.2mm
----------
a=30deg+-5deg b=42deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(40deg)
----------
aa=6.4+-0.03mm
----------
a=(40deg)
0000001901
(A): Pre-stroke actuator
(B): Stamp housings A and B at the same time.
(C): Stamping range
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (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 counterclockwise 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 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
Adjustment of the rack sensor (-0720)
1. Rack limit adjustment
(1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position.
(2)Install the rod (E) to the block (C).
(3)At the rack limit, set the distance between the pump end face and the rod (E) to L1.
2. Rack sensor
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at N1.
(3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
----------
L=33.5+-0.1mm N1=550r/min Ra=10.2mm
----------
----------
L=33.5+-0.1mm N1=550r/min Ra=10.2mm
----------
Information:
Starting System
Use a D.C. voltmeter to locate starting system components which do not function.Move starting control switch to energize the starter solenoid. Starter solenoid operation is audible as the starter motor pinion engages with the ring gear on the engine flywheel. The solenoid operation should also close the electric circuit to the motor. Attach one voltmeter lead to the solenoid terminal that is connected to the motor. Ground the other lead. Energize the starter solenoid and observe the voltmeter. A battery voltage reading indicates the malfunction is in the motor. It must be removed for further testing. No voltmeter reading indicates that the solenoid contacts do not close and the solenoid must be repaired or the starter pinion clearance should be adjusted.A starting motor solenoid that will not operate may not be receiving battery current. Attach one lead of the voltmeter to the solenoid battery cable connection. Ground the other lead. No voltmeter reading indicates a faulty circuit from the battery. A voltmeter reading indicates further testing is necessary.Continue the test by attaching one voltmeter lead to the starting motor solenoid small wire terminal and the other lead to ground. Observe the voltmeter and energize the starter solenoid. A voltmeter reading indicates that the malfunction is in the solenoid. No voltmeter reading indicates the starter switch or wiring is the fault.Attach one lead of the voltmeter to the starter switch battery wire terminal and ground the other lead. A voltmeter reading indicates a defective switch.A starting motor that operates too slow can be overloaded by excessive mechanical friction within the engine being started. Slow starting motor operation can also be caused by shorts, loose connections and/or excessive dirt within the motor.Pinion Clearance Adjustment (Prestolite)
There are two adjustments on this type motor. Armature end play and pinion position.Armature End Play
Adjust the end play to .005 to .030 in. (0.13 to 0.76 mm) by adding or removing thrust washers on the commutator end of the armature shaft.Pinion Position
This adjustment is accomplished in two steps.1. To adjust the pinion distance, connect the solenoid to a 12 volt battery as shown.Momentarily flash the jumper lead from the motor terminal stud of the solenoid to the terminal stud at (1) in the commutator end head to shift the solenoid and drive into the cranking position.
CONNECTIONS FOR ADJUSTING THE PINION POSITION
1. Jumper lead flashing point.Remove the jumper lead. The drive will remain in the cranking position until the battery is disconnected.Push the drive toward the commutator end of the motor to eliminate any slack movement in the linkage and measure the distance between the outside edge of the drive sleeve and the thrust washer. The distance (3) must be .02 to .05 in. (0.5 to 1.3 mm).Adjust to this dimension by turning the adjusting nut (2) in or out as required.
PINION POSITION ADJUSTMENT
2. Adjusting nut. 3. Distance.2. To test assembly of solenoid, it will be necessary to have an interference block cut to the dimensions shown.
INTERFERENCE BLOCK DIMENSIONSConnect the solenoid to 24 volts as
Use a D.C. voltmeter to locate starting system components which do not function.Move starting control switch to energize the starter solenoid. Starter solenoid operation is audible as the starter motor pinion engages with the ring gear on the engine flywheel. The solenoid operation should also close the electric circuit to the motor. Attach one voltmeter lead to the solenoid terminal that is connected to the motor. Ground the other lead. Energize the starter solenoid and observe the voltmeter. A battery voltage reading indicates the malfunction is in the motor. It must be removed for further testing. No voltmeter reading indicates that the solenoid contacts do not close and the solenoid must be repaired or the starter pinion clearance should be adjusted.A starting motor solenoid that will not operate may not be receiving battery current. Attach one lead of the voltmeter to the solenoid battery cable connection. Ground the other lead. No voltmeter reading indicates a faulty circuit from the battery. A voltmeter reading indicates further testing is necessary.Continue the test by attaching one voltmeter lead to the starting motor solenoid small wire terminal and the other lead to ground. Observe the voltmeter and energize the starter solenoid. A voltmeter reading indicates that the malfunction is in the solenoid. No voltmeter reading indicates the starter switch or wiring is the fault.Attach one lead of the voltmeter to the starter switch battery wire terminal and ground the other lead. A voltmeter reading indicates a defective switch.A starting motor that operates too slow can be overloaded by excessive mechanical friction within the engine being started. Slow starting motor operation can also be caused by shorts, loose connections and/or excessive dirt within the motor.Pinion Clearance Adjustment (Prestolite)
There are two adjustments on this type motor. Armature end play and pinion position.Armature End Play
Adjust the end play to .005 to .030 in. (0.13 to 0.76 mm) by adding or removing thrust washers on the commutator end of the armature shaft.Pinion Position
This adjustment is accomplished in two steps.1. To adjust the pinion distance, connect the solenoid to a 12 volt battery as shown.Momentarily flash the jumper lead from the motor terminal stud of the solenoid to the terminal stud at (1) in the commutator end head to shift the solenoid and drive into the cranking position.
CONNECTIONS FOR ADJUSTING THE PINION POSITION
1. Jumper lead flashing point.Remove the jumper lead. The drive will remain in the cranking position until the battery is disconnected.Push the drive toward the commutator end of the motor to eliminate any slack movement in the linkage and measure the distance between the outside edge of the drive sleeve and the thrust washer. The distance (3) must be .02 to .05 in. (0.5 to 1.3 mm).Adjust to this dimension by turning the adjusting nut (2) in or out as required.
PINION POSITION ADJUSTMENT
2. Adjusting nut. 3. Distance.2. To test assembly of solenoid, it will be necessary to have an interference block cut to the dimensions shown.
INTERFERENCE BLOCK DIMENSIONSConnect the solenoid to 24 volts as