2. Injection timing Pre-strok Pre-s troke: e: No No.. 1 Plunger Plunger 5.1 ± 0.03 0.03 mm Connector 1
Note:
Stopper 2 (Timing retard side)
1. Adjust using the shim 3. 2. Adjust with the rack in the full-load position. 3. Adjust with the connector 1 contacting the stopper 2.
Injection order: 1
4,1
60°± 15'
2,1
120°± 15'
6,1
180°± 15'
Shim 3
3,1
240°± 15'
5
300°± 15'
Plungers Plunge rs are numbered numbered from the Governo Governorr side. Tappet clearance: Manually rotate the camshaft 2 ~ 3 times and conrm that it rotates smoothly.
3. Pre-stroke actuator adjustment Pre-strok Pre-s troke e actuator actuator type: Retar Retard d Power sup uppl ply y vol volta tage ge::
24± 24 ±0. 0.5 5V
Pre-stroke (mm)
Pre-stroke sensor output voltage (V)
2. 0 ± 0.05
2.83 ± 0.01
5. 1 ± 0.03
V1 = 1.2 ± 0.2
-
Above 3.05
Ambientt tempe Ambien temperatur rature: e: 23±5° 23±5°C C Remarks Pre-stroke actuator adjustment Conrmation Conrmation (Pre-stroke actuator operating range)
Bosch Automotive Systems Corporation Service Department
107691-3570 2/6 Note: 1. Move the pre-stroke actuator fully clockwise (viewed from the drive side), and temporarily secure it to the actuator housing using the bolts. Tightening torque: 1.0 ~ 1.5 N•m {0.1 ~ 0.15 kgf•m} 2. Move the pre-stroke actuator counter clockwise (viewed from the drive side) to adjust it. 3. After pre-stroke actuator adjustment, stamp both the pre-stroke actuator and the housing with an aligning mark. Stamping position Pre-stroke actuator Injection pump
4. Injection quantity variation rate adjustment P = pre-stroke sensor output at injection quantity adjustment P1
V = 2.25 ± 0.01 (V)
3.1 ± 0.05 (mm)
P2
V =V1 + 0.05±0.01 (V)
5.0 ± 0.03 (mm)
Adjusting P point
Rack position (mm)
Pump speed (r/min)
12.7
750
-
P1
Z
P2 8.2±0.5
440
Injection q'ty (cm3 / 1000 strokes )
114.5 ± 3 Each cylinder 13.5±1.35
Max. variation between cylinders (%)
Fixed
Remarks
± 3.5
Rack
Basic
-
Rack
Adjust injection q'ty at N = 440. Adjust governor as per gov. adj. spec.
107691-3570 3/6 5. Governor adjustment Full load adjustment Torque cam no. ‘AH02’ Stop lever normal position setting: (18.0)
Boost compensator stroke: 1.15±0.1 ) m m ( n o i t i s o p k c a R
At No. 1 plunger’s beginning of injection position (Pre-stroke: 5.1±0.03 mm)
Ap pr o x . 3 0 ° Coupling key groove position
Flywheel
(Actual shapes and positions may differ from the illustration.) 1. Turn the pre-stroke actuator OFF. 2. Position the camshaft in the No.1 plunger's beginning of i njection position. 3. Conrm that the injection pump pointer's aligning mark and the ywheel's aligning mark are aligned. 4. If not aligned, remove the incorrect ywheel aligning mark and remark it. 5. Conrm that the center of the ywheel's threaded hole is as specied.
107691-3570 6/6 10. Rack sensor adjustment Amp-equipped rack sensor adjustment (154610-5*20) • Threaded type rack sensor (without rack limit; for P type, TICS) Rack sensor power supply
5±0.01V
Speed No
1250 r/min
Rack position Ro
R1(12.7) + 2.05 mm
Output voltage VR
3.00±0.01V
(1) Screw in bobbin 1 until it contacts the joint 2. (2) Fix the pump lever at full and screw in the bobbin 1 to adjust the depth so that the amp’s output voltage V = VR at Np = No and R = Ro. Then, x the rack sensor using the nut 6. (3) Move the pump lever 2 or 3 times, reset at full and conrm that the amp’s output voltage V = VR. (4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 - nut 6 join, and the pump end face - joint 2 join. Note: (1) When adjusting the bobbin 1 and joint 2, the fully tightened position of the bobbin is 9 threads (ie, 9 turns) from where it rst engages the joint. (2) With the welded rack block type, refer to the table below for the R = Ro range (the range varies with the joint). Rack sensor adjusting position
