108622-1140 ZEXEL 9 400 611 962 BOSCH INJECTION-PUMP ASSEMBLY 9400611962 1086221140 1156032940


108622-1140 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 611 962 9400611962
ZEXEL 108622-1140 1086221140
ISUZU 1156032940 1156032940

Service parts 108622-1140 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-3680
3. GOVERNOR 105923-4410
4. SUPPLY PUMP 105237-4740
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2261
7. COUPLING PLATE
10. NOZZLE AND HOLDER ASSY 105110-7731
11. Nozzle and Holder 1-15300-369-0
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.1{225}
13. NOZZLE-HOLDER 105041-4161
14. NOZZLE
15. NOZZLE SET 105019-2180

Include in #1:

108622-1140 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 962 9400611962
ZEXEL 108622-1140 1086221140
ISUZU 1156032940 1156032940


Zexel num
Bosch num
Firm num
Name
108622-1140 
108622-1141 
9 400 611 962 
1156032940  ISUZU
INJECTION-PUMP ASSEMBLY
6SD1-TC * K 14CJ TICS HD-TI6M TICS

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
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   255 255 255
Overflow valve opening pressure kgf/cm2   2.6 2.6 2.6
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.   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
Adjusting point   -
Rack position   12.9
Pump speed r/min   720 720 720
Average injection quantity mm3/st.   156.5 154.5 158.5
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   6.7+-0.5
Pump speed r/min   365 365 365
Average injection quantity mm3/st.   14.5 11.3 17.7
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-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(12.9)
Pump speed r/min   720 720 720
Average injection quantity mm3/st.   156.5 154.5 158.5
Basic   *
Fixing the lever   *
Boost pressure kPa   53.3 53.3
Boost pressure mmHg   400 400
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-1.7
Boost pressure kPa   8 6.7 9.3
Boost pressure mmHg   60 50 70
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2[R1-1. 4]
Boost pressure kPa   40 40 40
Boost pressure mmHg   300 300 300
0000001601
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:

Governor adjustment

Test data 108622-1140
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=AF76 BCL=1.7+-0.1mm
----------

Speed control lever angle

Test data 108622-1140
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=27.5deg+-5deg b=30deg+-3deg

Stop lever angle

Test data 108622-1140
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=22deg+-5deg b=41deg+-5deg

0000001301

Test data 108622-1140
(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove. (4)Damper (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
----------
aa=5deg bb=8.5+-0.03mm
----------
a=(50deg) b=(44deg)

0000001901

Test data 108622-1140
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 ACS

Test data 108622-1140
(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=1100r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3[R1+1.1]mm Rb=- Rc=(R3-1.1)mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2= - P3=70.1+-0.7kPa(526+-5mmHg) Q1=(141.5)cm3/1000st Q2=- Q3=126+-2cm3/1000st

0000002301 RACK SENSOR

Test data 108622-1140
G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.9)+1.1mm N1=1100r/min V1=3+-0.01V
----------




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108622-1140  

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INJECTION-PUMP ASSEMBLY
6WG1-TCN
9 400 611 860 
1156033062 
INJECTION-PUMP ASSEMBLY
6WG1-TCN
9 400 611 963 
1156033063 
INJECTION-PUMP ASSEMBLY
6WG1-TCN
9 400 612 241 
1156033064 
INJECTION-PUMP ASSEMBLY
6WG1-TCN
9 400 612 729 
1156033066 
INJECTION-PUMP ASSEMBLY
6WG1-TCN
9 400 612 959 
1156033067 
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6WG1-TCN
9 400 619 120 
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