Information injection-pump assembly
BOSCH
9 400 619 283
9400619283
ZEXEL
108822-2344
1088222344
Rating:
Cross reference number
BOSCH
9 400 619 283
9400619283
ZEXEL
108822-2344
1088222344
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
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
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
Adjusting point
-
Rack position
14.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148
146.4
149.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9+-0.5
Pump speed
r/min
355
355
355
Average injection quantity
mm3/st.
20.5
18.5
22.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
8.4+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148
147
149
Basic
*
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
146
142
150
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
0000001601
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:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Damper spring setting
----------
T1=AC23
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----------
T1=AC23
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Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=45mm
----------
a=3deg+-5deg b=31deg+-3deg
----------
aa=45mm
----------
a=3deg+-5deg b=31deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
(3)Normal engine position (equivalent to R = dd).
----------
aa=45mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=25.5deg+-5deg c=41deg+-5deg
----------
aa=45mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=25.5deg+-5deg c=41deg+-5deg
0000001301
(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)
0000001901
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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0000002201 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=8.9+-0.1mm
----------
----------
N1=325r/min Ra=8.9+-0.1mm
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0000002301 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 (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)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)
----------
N1=1100r/min Ra=R1(14.3)+1.5mm
----------
----------
N1=1100r/min Ra=R1(14.3)+1.5mm
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0000002401 LEVER
Speed lever cancel adjustment procedure (without dashpot)
(A) Top lever
(B) Bottom lever
(C) Return spring
1. At governor adjustment (FULL adjustment)
(1)Set high idle using the lever (A).
(2)Confirm that lever (A) is not cancelled with lever (B).
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Information:
Start By:a. remove valve covers
Typical Example1. Use Tool (A) to loosen the nuts and remove fuel lines (2).2. Disconnect fuel lines (1) from the valve cover base adapters.
Put protection caps (5F-2807) and plugs (2F-2990) on the fuel line openings to keep dirt and foreign material out of the fuel system.
3. Remove locks (3) and fuel line adapters (4) from the valve cover bases for clearance to remove the rocker shaft bolts. 4. Remove bolts (5) and rocker shaft assemblies (6) from the cylinder head. 5. Remove push rods (7) from the cylinder heads.6. Put identification on each valve bridge as to its location. Remove valve bridges (8) from the cylinder heads.Install Rocker Shaft Assemblies
1. Put clean engine oil on the bridge dowels, push rods (2) and inside bridges (1). Install bridges (1) and push rods (2) in the correct positions. 2. Push straight down on the top contact surface of valve bridge (1) with a force of 4 to 45 N (1 to 10 lb). Turn the adjustment screw clockwise until contact is made with the valve stem. Turn the adjustment screw 20 to 30 degrees more to keep bridge (1) straight on the dowel. Hold the adjustment screw in this position and tighten the locknut to a torque of 28 4 N m (22 3 lb ft). 3. Put rocker shaft assembly (3) in position on the cylinder head. Make sure the adjustment screws in the rocker arms are correctly engaged with the push rods. 4. Put clean engine oil on the threads of the bolts and install the bolts to hold rocker shaft assembly. Tighten the bolts as follows:a. Tighten bolts 1 through 6 in number sequence shown to a torque of 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 6 in number sequence shown to a torque of 447 20 N m (330 15 lb ft).c. Tighten bolts 1 through 6 in number sequence shown again to a torque of 447 20 N m (330 15 lb ft). 5. Put clean engine oil on the O-ring seals and install fuel line adapters (5), the washers, spaces, locks and nuts (4). Tighten nuts (4) to a torque of 14 3 N m (10 2 lb ft) 6. Install fuel lines (7) and connect fuel lines (6) to the fuel line adapters. Use Tool (A) and tighten the nuts for fuel lines (7). Tighten all fuel line nuts to a torque of 40 7 N m (30 5 lb ft).7. Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. See Valve Clearance Setting in Testing And Adjusting.End By:a. install valve covers Disassemble Rocker Shaft Assemblies
Start By:a. remove rocker shaft assemblies 1. Remove retainer (1) from the end of the shaft.2. Remove the washers and rocker arm (2). 3. Use Tool (A) to remove the pin that
Typical Example1. Use Tool (A) to loosen the nuts and remove fuel lines (2).2. Disconnect fuel lines (1) from the valve cover base adapters.
Put protection caps (5F-2807) and plugs (2F-2990) on the fuel line openings to keep dirt and foreign material out of the fuel system.
3. Remove locks (3) and fuel line adapters (4) from the valve cover bases for clearance to remove the rocker shaft bolts. 4. Remove bolts (5) and rocker shaft assemblies (6) from the cylinder head. 5. Remove push rods (7) from the cylinder heads.6. Put identification on each valve bridge as to its location. Remove valve bridges (8) from the cylinder heads.Install Rocker Shaft Assemblies
1. Put clean engine oil on the bridge dowels, push rods (2) and inside bridges (1). Install bridges (1) and push rods (2) in the correct positions. 2. Push straight down on the top contact surface of valve bridge (1) with a force of 4 to 45 N (1 to 10 lb). Turn the adjustment screw clockwise until contact is made with the valve stem. Turn the adjustment screw 20 to 30 degrees more to keep bridge (1) straight on the dowel. Hold the adjustment screw in this position and tighten the locknut to a torque of 28 4 N m (22 3 lb ft). 3. Put rocker shaft assembly (3) in position on the cylinder head. Make sure the adjustment screws in the rocker arms are correctly engaged with the push rods. 4. Put clean engine oil on the threads of the bolts and install the bolts to hold rocker shaft assembly. Tighten the bolts as follows:a. Tighten bolts 1 through 6 in number sequence shown to a torque of 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 6 in number sequence shown to a torque of 447 20 N m (330 15 lb ft).c. Tighten bolts 1 through 6 in number sequence shown again to a torque of 447 20 N m (330 15 lb ft). 5. Put clean engine oil on the O-ring seals and install fuel line adapters (5), the washers, spaces, locks and nuts (4). Tighten nuts (4) to a torque of 14 3 N m (10 2 lb ft) 6. Install fuel lines (7) and connect fuel lines (6) to the fuel line adapters. Use Tool (A) and tighten the nuts for fuel lines (7). Tighten all fuel line nuts to a torque of 40 7 N m (30 5 lb ft).7. Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. See Valve Clearance Setting in Testing And Adjusting.End By:a. install valve covers Disassemble Rocker Shaft Assemblies
Start By:a. remove rocker shaft assemblies 1. Remove retainer (1) from the end of the shaft.2. Remove the washers and rocker arm (2). 3. Use Tool (A) to remove the pin that