Information injection-pump assembly
BOSCH
9 400 611 868
9400611868
ZEXEL
108821-0200
1088210200
Rating:
Service parts 108821-0200 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-97175
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/18.6{190}
14.
NOZZLE
Include in #1:
108821-0200
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 868
9400611868
ZEXEL
108821-0200
1088210200
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
134424-4120
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
RED4 control unit part number
407915-0
590
RED4 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
41
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
8-7-5-4-
3-6-2-1
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 8-7 deg. 45 44.75 45.25
Cal 8-7 deg. 45 44.75 45.25
Difference between angles 2
Cal 8-5 deg. 90 89.75 90.25
Cal 8-5 deg. 90 89.75 90.25
Difference between angles 3
Cal 8-4 deg. 135 134.75 135.25
Cal 8-4 deg. 135 134.75 135.25
Difference between angles 4
Cal 8-3 deg. 180 179.75 180.25
Cal 8-3 deg. 180 179.75 180.25
Difference between angles 5
Cal 8-6 deg. 225 224.75 225.25
Cal 8-6 deg. 225 224.75 225.25
Difference between angles 6
Cal 8-2 deg. 270 269.75 270.25
Cal 8-2 deg. 270 269.75 270.25
Difference between angles 7
Cal 8-1 deg. 315 314.75 315.25
Cal 8-1 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(11.9)
PWM
%
55.2
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
126
124
128
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(7.7)
PWM
%
31.5+-2.
8
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
19
17
21
Max. variation between cylinders
%
0
-10
10
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
Governor adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
980
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
0000001201
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.
11.5
11
12
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
2.4
2.35
2.45
Output voltage
V
2.95
2.94
2.96
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
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=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(85deg)
----------
aa=6.4+-0.03mm
----------
a=(85deg)
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
(PWM) Pulse width modulation (%)
(R) Rack position (mm)
Rack sensor output characteristics
1. Rack limit adjustment
(1)Measure the rack position R2 for PWM a2%.
(2)Confirm that it is within the range R2 = 15+-1 mm.
(3)Measure the rack position R1 at PWM a %.
(4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm.
2. Check the limp home operation.
(1)Move the switch box's limp home switch to the limp home side.
(2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table.
3. Check the pull down operation.
(1)Confirm that the rack position is 19 mm at PWM B%.
(2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------
Information:
Charging System Components
Alternators
3T6352 Alternator
3T6352 Alternator
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.The alternator is driven by V-belts from the crankshaft pulley. This alternator is a three phase, self-rectifying charging unit, and the regulator is part of the alternator.This alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent on to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.The voltage regulator is a solid state (transistor, stationary parts) electronic switch. It feels the voltage in the system and switches on and off many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output.7N9720 Alternator
7N9720 Alternator
(1) Winding. (2) Stator. (3) Rectifier. (4) Rotor. (5) Non-magnetic ring.The alternator is driven by two V-belts. It has a three phase full wave rectified output. The alternator is brushless.The rotor (4) and the bearings are the only moving parts. The 7N9720 Alternator has an output of 37A. The 9G9538 Alternator has an output of 50A.The main parts of the alternator are the stator (2) which has three phase windings, the rectifier (3) which changes the three phase AC to DC and provides excitation current.The field winding (1) is a stationary coil assembly that provides the magnetic field.The rotor provides the north and south poles which cut the magnetic field between the stationary field winding and the stator (2). North and south poles are separated magnetically by a non-magnetic ring (5).9G4574 Alternator
9G4574 Alternator
(1) Fan. (2) Front frame assembly. (3) Stator assembly. (4) Rotor assembly. (5) Field winding (coil assembly). (6) Regulator assembly. (7) Condenser (suppression capacitor). (8) Rectifier assembly. (9) Rear frame assembly.This alternator has three-phase, full-wave rectified output. It is
Alternators
3T6352 Alternator
3T6352 Alternator
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.The alternator is driven by V-belts from the crankshaft pulley. This alternator is a three phase, self-rectifying charging unit, and the regulator is part of the alternator.This alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent on to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.The voltage regulator is a solid state (transistor, stationary parts) electronic switch. It feels the voltage in the system and switches on and off many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output.7N9720 Alternator
7N9720 Alternator
(1) Winding. (2) Stator. (3) Rectifier. (4) Rotor. (5) Non-magnetic ring.The alternator is driven by two V-belts. It has a three phase full wave rectified output. The alternator is brushless.The rotor (4) and the bearings are the only moving parts. The 7N9720 Alternator has an output of 37A. The 9G9538 Alternator has an output of 50A.The main parts of the alternator are the stator (2) which has three phase windings, the rectifier (3) which changes the three phase AC to DC and provides excitation current.The field winding (1) is a stationary coil assembly that provides the magnetic field.The rotor provides the north and south poles which cut the magnetic field between the stationary field winding and the stator (2). North and south poles are separated magnetically by a non-magnetic ring (5).9G4574 Alternator
9G4574 Alternator
(1) Fan. (2) Front frame assembly. (3) Stator assembly. (4) Rotor assembly. (5) Field winding (coil assembly). (6) Regulator assembly. (7) Condenser (suppression capacitor). (8) Rectifier assembly. (9) Rear frame assembly.This alternator has three-phase, full-wave rectified output. It is