Information injection-pump assembly
BOSCH
9 400 619 895
9400619895
ZEXEL
108822-2010
1088222010
Rating:
Service parts 108822-2010 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/24.5{250}
14.
NOZZLE
Include in #1:
108822-2010
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 895
9400619895
ZEXEL
108822-2010
1088222010
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
105780-8230
Nozzle
105780-0110
Bosch type code
DN0SN059
Nozzle holder
105780-2170
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
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
407910-2
470
RED3 rack sensor specifications
mm
15
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
42
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
1-2-7-3-
4-5-6-8
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
Cyl.1-2 deg. 45 44.75 45.25
Cyl.1-2 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25
Cal 1-8 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(11.3)
Vist
V
1.73
1.73
1.73
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
119.5
118.5
120.5
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_02
Rack position
(7.5)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
23
21
25
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=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-5deg
----------
aa=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-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=6deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
----------
aa=6deg bb=8.5+-0.03mm
----------
a=(45deg) 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 15 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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----------
----------
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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=1V
----------
----------
V1=1V
----------
Information:
(1) Diameter of rocker shaft ... 19.012 to 19.037 mm (.7485 to .7495 in.) Overall length ... 661.1938 mm (26.03125 in.)(2) Inside diameter of rocker arm ... 22.23 to 22.255 mm (.875 go .8762 in.)(3) Outside diameter of bushing ... 22.28 to 22.314 mm (.877 to .8785 in.) Interference fit of bushing in rocker lever ... 0.020 to 0.089 mm (.0008 to .0035 in.)Inside diameter of bushing (after it's reamed) ... 19.063 to 19.101 mm (.7505 to .7520 in.)Clearance of rocker shaft in bushing ... 0.03 to 0.089 mm (.001 to .0035 in.)Maximum permissible clearance ... 0.13 mm (.005 in.) See Rocker Shaft Assembly in TESTING AND ADJUSTING for proper alignment of the oil holes in the bushing and rocker lever.(4) Torque for bolts and nuts that hold rocker shaft assembly to cylinder head (tighten bolts from center outward) ... 75 N m (55 lb.ft.)(5) Install seal in cylinder head before rocker shaft assembly is installed.(6) Overall length of push rod ... 265.58 to 267.72 mm (10.456 to 10.540 in.) Shank diameter ... 7.87 to 7.92 mm (.310 to .312 in.)(7) Tappets (valve lifters): Overall length ... 75.4063 mm (2.96875 in.)Shank outside diameter ... 18.987 to 19.012 mm (.7475 to .7485 in.)Cylinder block tappet bore diameter ... 19.05 to 19.0818 mm (.750 to .75125 in.)Running clearance between tappet and block ... 0.038 to 0.0953 mm (.0015 to .00375 in.)Outside diameter of tappet foot ... 30.163 mm (1.1875 in.) (8) Diameter of camshaft journals: No. 1 journal ... 50.71 to 50.737 mm (1.9965 to 1.9975 in.)Minimum permissible diameter ... 50.660 mm (1.9945 in.)No. 2 journal ... 50.457 to 50.483 mm (1.9865 to 1.9875 in.)Minimum permissible diameter ... 50.406 mm (1.9845 in.)No. 3 journal ... 50.203 to 50.229 mm (1.9765 to 1.9775 in.)Minimum permissible diameter ... 50.152 mm (1.9745 in.)No. 4 journal ... 49.949 to 49.975 mm (1.9665 to 1.9675 in.)Minimum permissible diameter ... 48.898 mm (1.9645 in.)(See topic Cylinder Block for camshaft bore specifications.) (10) Height of the lobes of the camshaft. To get height use the procedure that follows:A. Measure base circle (11).B. Add lobe lift (9) to base circle measurement. Total is camshaft lobe height. Camshaft lobe lift (9) is:Intake ... 7.704 to 7.780 mm (.3033 to .3063 in.)Exhaust ... 7.805 to 7.881 mm (.3073 to .3103 in.)Minimum permissible height of lobes is 0.25 mm (.010 in.) less than measurement in Step B.(12) Torque for camshaft bolt ... 70 N m (50 lb.ft.)(13) End play of camshaft ... 0.10 to 0.41 mm (.004 to .016 in.) Maximum permissible end play ... 0.53 mm (.021 in.)(14) Camshaft thrust washer: Outside diameter ... 72.95 to 73.00 mm (2.872 to 2.874 in.)Cylinder block recess diameter for thrust washer ... 73.03 to 73.28 mm (2.875 to 2.885 in.)Clearance of washer in recess ... 0.03 to 0.33 mm (.001 to .013 in.)Inside diameter ... 44.45 mm (1.750 in.)Thickness ... 5.49 to 5.54 mm (.216 to .218 in.)Cylinder block