107492-2014 ZEXEL 9 400 618 842 BOSCH INJECTION-PUMP ASSEMBLY 9400618842 1074922014

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 842 9400618842

ZEXEL 107492-2014 1074922014

Service parts 107492-2014 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107049-3020

3. GOVERNOR 105921-5283

4. SUPPLY PUMP 105237-6080

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-3821

8. _ 159590-3321

9. _

10. NOZZLE AND HOLDER ASSY 105118-5381

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3730

14. NOZZLE 105017-1221

15. NOZZLE SET

Include in #1:

107492-2014 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 842 9400618842

ZEXEL 107492-2014 1074922014

Zexel num

Bosch num

Firm num

Name

107492-2014
107492-2015

9 400 618 842

INJECTION-PUMP ASSEMBLY
4D34T3 * K 14CF TICS MD-TI4 TICS

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-8420

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

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 12.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 99.5 97.9 101.1

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

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 720 720 720

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 99.5 98.5 100.5

Basic *

Fixing the lever *

Boost pressure kPa 41.3 41.3

Boost pressure mmHg 310 310

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.75

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 108.8 104.8 112.8

Fixing the lever *

Boost pressure kPa 41.3 41.3

Boost pressure mmHg 310 310

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_05

Adjusting point C

Rack position R2+(1.3)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 93.7 89.7 97.7

Fixing the lever *

Boost pressure kPa 41.3 41.3

Boost pressure mmHg 310 310

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_06

Adjusting point D

Rack position R2(R1-2. 05)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 53.6 49.6 57.6

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 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_07

Adjusting point E

Rack position (R1+1.2)

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 107.3 103.3 111.3

Fixing the lever *

Boost pressure kPa 41.3 41.3

Boost pressure mmHg 310 310

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2(R1-2. 05)

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2+(1.3)

Boost pressure kPa 28 28 28

Boost pressure mmHg 210 210 210

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 *

_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 *

_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=G56 BCL=(1.3)+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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a=23deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
----------
aa=1600r/min bb=4.5-0.5mm
----------
a=36.5deg+-5deg b=38deg+-5deg

0000001301

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)

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)
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N1=1500r/min Ra=R1(12.1)+1.75mm
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