Information injection-pump assembly
BOSCH
9 400 611 489
9400611489
ZEXEL
108822-3265
1088223265
HINO
220401194A
220401194a
Rating:
Service parts 108822-3265 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
23600-3160A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/23.5{240}
14.
NOZZLE
Include in #1:
108822-3265
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 489
9400611489
ZEXEL
108822-3265
1088223265
HINO
220401194A
220401194a
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
RED3 control unit part number
407910-3
960
RED3 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
1-8-6-2-
7-5-4-3
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 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 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(14.1)
Vist
V
1.73
1.73
1.73
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
193
191
195
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(6.5)
Vist
V
2.9
2.8
3
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
18.1
17.1
19.1
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
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=37deg+-5deg b=8deg+-5deg
----------
aa=20mm bb=1mm
----------
a=37deg+-5deg b=8deg+-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)Pre-stroke: aa
(7)-
----------
aa=6.4+-0.03mm
----------
a=(80deg)
----------
aa=6.4+-0.03mm
----------
a=(80deg)
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 19 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.
----------
----------
----------
----------
Information:
Introduction
This Special Instruction provides information in order to prolong the life of the cutting bits on the PM-465 rotor. An additional spray nozzle was added to the left side of the chamber.Rework Procedure
Table 1
Required Parts
Quantity Part Number Description
1 211-8607 Tube
1 211-8604 Plate
1 1G-6699 Adapter
1 1G-8270 Nozzle Body
2 5D-1026 Hose Clamp
1000 mm (39 inch) 5P-1690 Hose
1 081-2963 Cap
1 081-2965 Seal
1 115-9969 Male Connector
1 115-9970 Male Connector
1 212-0911 Nozzle
Illustration 1 g00853436
(A) 573 mm (22.56 inches) (B) 102.5 mm (4 inches) (C) 150 mm (5.91 inches)
Remove 142-7461 Plate (1) from the chamber.
Relocate the 142-7461 Plate (1) .
The new location of the 142-7461 Plate (1) should measure 150 mm (5.91 inches) (C) from the top of the chamber. The center of the 142-7461 Plate should remain at 573 mm (22.56 inches) (A) .
Cut a slot in the left side of the chamber that is 40 mm (1.57 inch) by 85 mm (3.35 inch). The center of the slot should measure 102.5 mm (4 inches) from the top (B) of the chamber and 573 mm (22.56 inches) from the front (A) of the chamber. Refer to Illustration 1.
Illustration 2 g00853889
Weld the 211-8604 Plate (2) in the slot. The plate should be flush with the inside of the chamber. Face the open end of the plate downward in the slot.
Illustration 3 g00853468
Illustration 4 g00853890
(D) 20 mm (0.79 inch) (E) 8.5 mm (0.33 inch)
Weld a 211-8607 Tube (3) onto the side of the chamber. Position the bottom of the tube 20 mm (0.79 inch) (D) from the bottom of the slot and 8.5 mm (0.33 inch) (E) to the right of the slot. Refer to Illustration 4.
Illustration 5 g00853470
Remove hose assembly (4) from the nozzle (5) that is located near the left side of the chamber.
Replace connector (6) with 115-9970 Male Connector .
Illustration 6 g00863254
Use the following parts in order to assemble a new nozzle: 115-9969 Male Connector (7), 1G-6699 Adapter (8), 1G-8270 Nozzle Body (9), 212-0911 Nozzle (10), 081-2965 Seal (11) and 081-2963 Cap (12) .
Illustration 7 g00853509
Place the new nozzle assembly in tube (13) that is located on the side of the chamber.Note: The flat spray pattern of the nozzle should be parallel to the slot.
Connect the two nozzles with a 5P-1690 Hose . Use two 5D-1026 Hose Clamps in order to secure the hose to the nozzles.
This Special Instruction provides information in order to prolong the life of the cutting bits on the PM-465 rotor. An additional spray nozzle was added to the left side of the chamber.Rework Procedure
Table 1
Required Parts
Quantity Part Number Description
1 211-8607 Tube
1 211-8604 Plate
1 1G-6699 Adapter
1 1G-8270 Nozzle Body
2 5D-1026 Hose Clamp
1000 mm (39 inch) 5P-1690 Hose
1 081-2963 Cap
1 081-2965 Seal
1 115-9969 Male Connector
1 115-9970 Male Connector
1 212-0911 Nozzle
Illustration 1 g00853436
(A) 573 mm (22.56 inches) (B) 102.5 mm (4 inches) (C) 150 mm (5.91 inches)
Remove 142-7461 Plate (1) from the chamber.
Relocate the 142-7461 Plate (1) .
The new location of the 142-7461 Plate (1) should measure 150 mm (5.91 inches) (C) from the top of the chamber. The center of the 142-7461 Plate should remain at 573 mm (22.56 inches) (A) .
Cut a slot in the left side of the chamber that is 40 mm (1.57 inch) by 85 mm (3.35 inch). The center of the slot should measure 102.5 mm (4 inches) from the top (B) of the chamber and 573 mm (22.56 inches) from the front (A) of the chamber. Refer to Illustration 1.
Illustration 2 g00853889
Weld the 211-8604 Plate (2) in the slot. The plate should be flush with the inside of the chamber. Face the open end of the plate downward in the slot.
Illustration 3 g00853468
Illustration 4 g00853890
(D) 20 mm (0.79 inch) (E) 8.5 mm (0.33 inch)
Weld a 211-8607 Tube (3) onto the side of the chamber. Position the bottom of the tube 20 mm (0.79 inch) (D) from the bottom of the slot and 8.5 mm (0.33 inch) (E) to the right of the slot. Refer to Illustration 4.
Illustration 5 g00853470
Remove hose assembly (4) from the nozzle (5) that is located near the left side of the chamber.
Replace connector (6) with 115-9970 Male Connector .
Illustration 6 g00863254
Use the following parts in order to assemble a new nozzle: 115-9969 Male Connector (7), 1G-6699 Adapter (8), 1G-8270 Nozzle Body (9), 212-0911 Nozzle (10), 081-2965 Seal (11) and 081-2963 Cap (12) .
Illustration 7 g00853509
Place the new nozzle assembly in tube (13) that is located on the side of the chamber.Note: The flat spray pattern of the nozzle should be parallel to the slot.
Connect the two nozzles with a 5P-1690 Hose . Use two 5D-1026 Hose Clamps in order to secure the hose to the nozzles.