Rating:
Information injection-pump assembly
BOSCH
9 400 618 843
9400618843
ZEXEL
107492-2025
1074922025
Service parts 107492-2025 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107492-2025
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 843
9400618843
ZEXEL
107492-2025
1074922025
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
105780-8140
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
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
7.4+-0.5
Pump speed
r/min
780
780
780
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
37.3
37.3
Boost pressure
mmHg
280
280
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
37.3
37.3
Boost pressure
mmHg
280
280
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
37.3
37.3
Boost pressure
mmHg
280
280
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
37.3
37.3
Boost pressure
mmHg
280
280
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
12
10.7
13.3
Boost pressure
mmHg
90
80
100
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2+(1.3)
Boost pressure
kPa
24
24
24
Boost pressure
mmHg
180
180
180
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
----------
----------
T1=G56 BCL=(1.3)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=22.5deg+-5deg b=(38deg)+-3deg
----------
----------
a=22.5deg+-5deg b=(38deg)+-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
----------
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)
----------
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.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
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=1500r/min Ra=R1(12.1)+1.75mm
----------
----------
N1=1500r/min Ra=R1(12.1)+1.75mm
----------