108622-3454 ZEXEL 9 400 619 745 BOSCH INJECTION-PUMP ASSEMBLY 9400619745 1086223454

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 745 9400619745

ZEXEL 108622-3454 1086223454

Service parts 108622-3454 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3271

3. GOVERNOR 105489-5082

4. SUPPLY PUMP 105237-4690

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0740

7. COUPLING PLATE 156638-9920

8. _ 159600-2221

9. _

10. NOZZLE AND HOLDER ASSY 105101-7892

11. Nozzle and Holder 23600-2781A

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/23.5{240}

13. NOZZLE-HOLDER 105030-3612

14. NOZZLE

15. NOZZLE SET 105019-0550

Include in #1:

108622-3454 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 745 9400619745

ZEXEL 108622-3454 1086223454

Zexel num

Bosch num

Firm num

Name

108622-3454
108622-3455

9 400 619 745

INJECTION-PUMP ASSEMBLY
* 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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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. 33

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.8

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 185.5 183.5 187.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Adjusting point B

Rack position 11.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 199 196 202

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_03

Adjusting point C

Rack position 11.3+-0. 5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 203 197 209

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 260 255 265

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Rack limit *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_05

Adjusting point E

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.5 5.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_06

Adjusting point F

Rack position R1(8.6)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 146.5 143.5 149.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_07

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1(8.6)

Boost pressure kPa 26.7 26.7 28.7

Boost pressure mmHg 200 200 215

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position 10.8

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position (11.6)

Boost pressure kPa 53.3 53.3 53.3

Boost pressure mmHg 400 400 400

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

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 2.4 2.35 2.45

Output voltage V 2.95 2.94 2.96

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

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

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Supplied with torque spring not set. (3)Stop lever setting: R1 (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Damper spring setting (7)Set idle at point K (N = N1, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). The prestroke at this time must be Pr1 (Pv1). ************
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R1=(13.1)+0.5mm BCL=(3)mm N1=325r/min R2=3.8mm N2=1000r/min Q1=3mm3/st Pr1=4+-0.05mm Pv1=2.2+-0.01V
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Speed control lever angle

F:Full speed
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a=(14.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=45mm
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a=26deg+-5deg b=36.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the rack position at bb before adjusting the governor (3)Set the stopper screw. (After setting, apply red paint.)
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aa=33mm bb=(13.1)+0.5mm
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a=36deg+-5deg b=44deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(10deg)

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 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
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N1=500r/min N2=(665)r/min N3=(755)r/min N4=1000r/min RF=10.8mm Dr1=0.5mm Dr2=0+0.3mm
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0000002301 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-0720) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (E) to the block (C). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
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L=33.5+-0.1mm N1=1000r/min Ra=11.3mm
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