107492-0107 ZEXEL 9 400 612 083 BOSCH INJECTION-PUMP ASSEMBLY 9400612083 1074920107

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 083 9400612083

ZEXEL 107492-0107 1074920107

Service parts 107492-0107 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107049-3160

3. GOVERNOR 105923-4476

4. SUPPLY PUMP 105237-5440

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-0020

8. _ 159601-4220

9. _

10. NOZZLE AND HOLDER ASSY 105118-6544

11. Nozzle and Holder 16600-29D01

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-4130

14. NOZZLE 105017-9120

15. NOZZLE SET

Include in #1:

107492-0107 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 083 9400612083

ZEXEL 107492-0107 1074920107

Zexel num

Bosch num

Firm num

Name

107492-0107
107492-0108

9 400 612 083

INJECTION-PUMP ASSEMBLY
FD46TA * K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131425-0520

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

PS/ACT control unit part no. 407910-3 03*

Selector switch no. 02

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 01

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 13.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 104.5 102.5 106.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.5+-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 12 10.2 13.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

PS407910-303* V V1+0.05+ -0.01

PS407910-303* mm 5.5+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.9)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 104.5 103.5 105.5

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+3.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 120.5 116.5 124.5

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-2.2)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 66 64 68

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position (R2-2.2)

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-1. 25)

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

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)Boost compensator stroke: BCL
----------
T1=AG72 BCL=(2.2)mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=58mm
----------
a=22.5deg+-5deg b=41.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Stopper bolt setting (3)Rack position = bb (speed = cc)
----------
aa=34mm bb=1.5+-0.3mm cc=0r/min
----------
a=22.5deg+-5deg b=45deg+-5deg

0000001301

(1)Pump vertical direction (2)Position of coupling's standard threaded hole at No 1 cylinder's beginning of injection (3)A.T.D.C: aa (4)Pre-stroke: bb
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(50deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001701

A : Stopper pin B: Connector
----------

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0000001801

C:Shim
----------

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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 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=1400r/min Ra=R1(13.9)+3.15mm
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0000002301 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Lever 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. (2)Select C so that dimension L2 can be obtained. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Set to full boost. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=1400r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+3.15)mm Rb=(R3-0.25)mm Rc=R3-0.75mm P1=(93.2)kPa((699)mmHg) P2=84.5+-2.7kPa(634+-20mmHg) P3=70.1+-0.7kPa(526+-5mmHg) Q1=120.5+-4cm3/1000st Q2=116.5+-10cm3/1000st Q3=112+-10cm3/1000st

0000002401 POTENTIO METER

(A) : Governor plan view (B): Potentiometer harness terminal (C): Potentiometer connection diagram (D) : Output voltage standard value (S): Voltage P/M: potentiometer (v): output voltage (V) (p): direction of potentiometer rotation 1. Adjustment procedures (1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage. (2)Fix the speed lever at the full side. (3)Loosen the bolt (S), and move the potentiometer from left and right. (4)Adjust so that the output voltage at full is within the standard values. (5)Fix bolt (S). (6)Repeatedly move the speed lever from the full side to the idle side. (7)Check that it is within the standard values at full and idle.
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V1=5+-0.02V
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V1=5+-0.02V Va=(5)V Vb=4.3+-0.05V Vc=-