108622-1001 ZEXEL 9 400 612 856 BOSCH INJECTION-PUMP ASSEMBLY 9400612856 1086221001


108622-1001 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 856 9400612856
ZEXEL 108622-1001 1086221001

Service parts 108622-1001 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-3110
3. GOVERNOR 105952-1001
4. SUPPLY PUMP 105237-6160
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2060
7. COUPLING PLATE
10. NOZZLE AND HOLDER ASSY 105110-4481
11. Nozzle and Holder 1-15300-315-2
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105041-4090
14. NOZZLE 105015-9731
15. NOZZLE SET

Include in #1:

108622-1001 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 856 9400612856
ZEXEL 108622-1001 1086221001


Zexel num
Bosch num
Firm num
Name
108622-1001 
108622-1002 
9 400 612 856 
   
INJECTION-PUMP ASSEMBLY
* 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   131424-7120
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.   32
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   8.5 8.47 8.53
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.75 60.25
Difference between angles 2
Cal 1-3
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cyl.1-2
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-4
deg.   300 299.75 300.25
Injection quantity adjustment
Rack position   (14.1)
Vist V   1.73 1.73 1.73
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   176 174 178
Max. variation between cylinders %   0 -3 3
Basic   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Injection quantity adjustment_02
Rack position   (7.3)
Vist V   2.8 2.7 2.9
Pump speed r/min   390 390 390
Average injection quantity mm3/st.   16 12.8 19.2
Max. variation between cylinders %   0 -13 13
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-0.0 3
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_03
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   142 122 142
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Remarks
Rack position, Vist are actual measurements. Stop lever setting.
 
0000001201
Pre-stroke mm   8.5 8.47 8.53
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   8.5 8 9
Remarks
When the eccentric pin is tightened
 
_03
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   6.1 6.05 6.15
Output voltage V   2.45 2.44 2.46
Adjustment   *
_04
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   8.5 8.47 8.53
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_05
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.5
Output voltage V   3 2.98 3
Confirmation   *
_06
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

Test data 108622-1001
N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=1mm
----------
a=37deg+-5deg b=37deg+-5deg

0000000901

Test data 108622-1001
(1)Pump vertical direction (2)Position of damper's threaded hole at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=8.5+-0.03mm
----------
a=(100deg)

0000001501

Test data 108622-1001
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

Test data 108622-1001
(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.
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