Information injection-pump assembly
BOSCH
9 400 619 978
9400619978
ZEXEL
108822-2580
1088222580
Rating:
Service parts 108822-2580 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
ME094539
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
108822-2580
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 978
9400619978
ZEXEL
108822-2580
1088222580
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
13.4
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
144.5
142.9
146.1
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
8.7+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
23.5
20.9
26.1
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(13.4)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
144.5
143.5
145.5
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+1.75
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
149.5
145.5
153.5
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.65
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
141.5
137.5
145.5
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_06
Adjusting point
E
Rack position
R1-1.05
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
149
145
153
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=AE51
----------
----------
T1=AE51
----------
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=37.5mm
----------
a=34deg+-5deg b=31.5deg+-3deg
----------
aa=37.5mm
----------
a=34deg+-5deg b=31.5deg+-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=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
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=4deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
----------
aa=4deg 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.
----------
----------
----------
----------
0000002201 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(13.4)+1.75mm
----------
----------
N1=1100r/min Ra=R1(13.4)+1.75mm
----------
Information:
start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove the bolts (1) that hold the governor housing (2) to the fuel injection pump housing.3. Remove the governor housing (2). 4. Remove two springs (4) and the seat (5) from the governor housing.5. Remove the seat (7) from the shaft.6. Remove the spring (6) from the shaft.7. Remove the cover (3) from the pump housing. 8. Remove the shaft (8) and the lever (9) from the pump housing. 9. Remove the thrust collar (11) from the shaft.10. Remove the cover (10) from the pump housing. 11. Loosen the two bolts (13) that hold the torque spring assembly (12) and remove it from the pump housing. 12. Remove the pin (15) from the pump housing.13. Remove the screw (14) and the nut (16) from the pump housing.14. Remove the ring that holds the lever and remove the lever (18) from the dowel (17).15. Remove the dowel (17) from the pump housing. Dowel does not need to be removed unless camshaft is to be removed.
Pull on the shield only a small amount in each location so it will not have distortion or damage. A damaged shield must be replaced.
16. Remove the shield (19) from the camshaft with tool (B). 17. Install the timing pin (C) to hold the camshaft.18. Remove the bolts (20) that hold the flyweight assembly to the camshaft. 19. Remove the flyweight assembly (21) from the camshaft.20. Remove the timing pin (C) from the pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on the bracket assembly (A).2. Install the timing pin (B) to hold the camshaft.3. Put the flyweight assembly (1) in position on the camshaft. Be sure the pin that holds the shaft (2) is in position on the back of the flyweight assembly.4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 10 2 lb. ft. (1.38 0.28 mkg).5. Remove the timing pin (B). 6. Put the shield (3) in position over the flyweights. 7. Use the driver (C) to install the shield the remainder of the way on to the camshaft. 8. Put a new O-ring seal on the dowel (4) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing. 9. Put the lever (8) on the dowel (4) and install the ring that holds it on the dowel.10. Install the screw (6) and the nut (7) in the pump housing.11. Install the pin (5) in the pump housing. 12. Put the torque spring assembly (10) in position on the housing and tighten the two bolts (11) that hold it to the housing.13. Install the cover (9) on the pump housing. 14. Put the thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire
Pull on the shield only a small amount in each location so it will not have distortion or damage. A damaged shield must be replaced.
16. Remove the shield (19) from the camshaft with tool (B). 17. Install the timing pin (C) to hold the camshaft.18. Remove the bolts (20) that hold the flyweight assembly to the camshaft. 19. Remove the flyweight assembly (21) from the camshaft.20. Remove the timing pin (C) from the pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on the bracket assembly (A).2. Install the timing pin (B) to hold the camshaft.3. Put the flyweight assembly (1) in position on the camshaft. Be sure the pin that holds the shaft (2) is in position on the back of the flyweight assembly.4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 10 2 lb. ft. (1.38 0.28 mkg).5. Remove the timing pin (B). 6. Put the shield (3) in position over the flyweights. 7. Use the driver (C) to install the shield the remainder of the way on to the camshaft. 8. Put a new O-ring seal on the dowel (4) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing. 9. Put the lever (8) on the dowel (4) and install the ring that holds it on the dowel.10. Install the screw (6) and the nut (7) in the pump housing.11. Install the pin (5) in the pump housing. 12. Put the torque spring assembly (10) in position on the housing and tighten the two bolts (11) that hold it to the housing.13. Install the cover (9) on the pump housing. 14. Put the thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire