Information injection-pump assembly
BOSCH
9 400 619 476
9400619476
ZEXEL
108822-2490
1088222490
Rating:
Service parts 108822-2490 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
14.
NOZZLE
Include in #1:
108822-2490
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 476
9400619476
ZEXEL
108822-2490
1088222490
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
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
(11.5)
Vist
V
1.69
1.69
1.69
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
127.5
126.5
128.5
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
(7.4)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
23.5
20.9
26.1
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=4deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
----------
aa=4deg 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.
----------
----------
----------
----------
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.
----------
----------
----------
----------
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:
Start By:a. remove exhaust manifoldsb. remove push rods and valve liftersc. remove water temperature regulators Put protection caps on all fuel openings. 1. Remove the bolts and valve cover base (1) from the cylinder head assembly.2. Disconnect hose (2) from the cylinder head assembly. 3. Put identification marks on wires (3), and disconnect them from the sending unit. 4. Remove six head bolts (4), and install Tooling (A). 5. Fasten a hoist to Tooling (A), and remove the remainder of the bolts that fasten the head assembly.6. Remove cylinder head assembly (5). The weight of the head assembly is 102 kg (224 lb). A new spacer plate gasket must be installed when the cylinder head is removed. See Remove & Install Spacer Plate.Install Cylinder Head Assemblies
1. Thoroughly clean the spacer plates and bottom surface of the cylinder head assemblies. Install a new head gasket and seals. Do not use any adhesives. A new spacer plate gasket must be installed when the cylinder head assembly is removed. See Remove And Install Spacer Plate. 2. Fasten Tooling (A) to the cylinder head assembly, and put cylinder head assembly (1) into position on the spacer plate. The use of guide bolts will help put the cylinder head assembly in alignment with the spacer plate.
(1) Large bolts (3/4 in). Put 6V-4876 Molycoat Paste Lubricant on the threads and between washer and underside of the cylinder head bolts. (2) Small bolts (3/8 in). See Step 3h.3. Install cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten bolts 1 through 10 in number sequence to 270 25 N m (200 20 lb ft)b. Tighten bolts 1 through 10 in number sequence to 470 20 N m (345 15 lb ft)c. Tighten bolts 1 through 10 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves.e. Tighten bolts 11 through 18 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 11 through 18 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 11 through 18 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the nine small bolts (2) to 45 7 N m (33 5 lb ft). 4. Connect hose (3) and the wire assembly to the cylinder head. 5. Install valve cover base (2) to the cylinder head. Tighten the bolts to a torque of 14 4 N m (10 3 lb ft) and the sequence as shown.End By:a. install water temperature regulatorsb. install push rods and valve liftersc. install exhaust manifolds
1. Thoroughly clean the spacer plates and bottom surface of the cylinder head assemblies. Install a new head gasket and seals. Do not use any adhesives. A new spacer plate gasket must be installed when the cylinder head assembly is removed. See Remove And Install Spacer Plate. 2. Fasten Tooling (A) to the cylinder head assembly, and put cylinder head assembly (1) into position on the spacer plate. The use of guide bolts will help put the cylinder head assembly in alignment with the spacer plate.
(1) Large bolts (3/4 in). Put 6V-4876 Molycoat Paste Lubricant on the threads and between washer and underside of the cylinder head bolts. (2) Small bolts (3/8 in). See Step 3h.3. Install cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten bolts 1 through 10 in number sequence to 270 25 N m (200 20 lb ft)b. Tighten bolts 1 through 10 in number sequence to 470 20 N m (345 15 lb ft)c. Tighten bolts 1 through 10 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves.e. Tighten bolts 11 through 18 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 11 through 18 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 11 through 18 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the nine small bolts (2) to 45 7 N m (33 5 lb ft). 4. Connect hose (3) and the wire assembly to the cylinder head. 5. Install valve cover base (2) to the cylinder head. Tighten the bolts to a torque of 14 4 N m (10 3 lb ft) and the sequence as shown.End By:a. install water temperature regulatorsb. install push rods and valve liftersc. install exhaust manifolds