108622-3750 ZEXEL 9 400 612 511 BOSCH INJECTION-PUMP ASSEMBLY 9400612511 1086223750

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 511 9400612511

ZEXEL 108622-3750 1086223750

Service parts 108622-3750 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3650

3. GOVERNOR 105923-4070

4. SUPPLY PUMP 105237-4690

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0740

7. COUPLING PLATE 156638-7720

8. _ 159601-3020

9. _

10. NOZZLE AND HOLDER ASSY 105101-8451

11. Nozzle and Holder 23600-3270B

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/27.5{280}

13. NOZZLE-HOLDER 105030-3750

14. NOZZLE

15. NOZZLE SET 105019-2220

Include in #1:

108622-3750 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 511 9400612511

ZEXEL 108622-3750 1086223750

Zexel num

Bosch num

Firm num

Name

108622-3750
108622-3751

9 400 612 511

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 134424-4120

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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 33

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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 -

Rack position 14.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 165.5 162.5 168.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 15 14 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-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(14.6)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 165.5 163.5 167.5

Basic *

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 147 141 153

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_05

Adjusting point C

Rack position R2-1.6

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 120 114 126

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 300 300 300

Rack position R2-1.6

Boost pressure kPa 32 30.7 33.3

Boost pressure mmHg 240 230 250

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 55)

Boost pressure kPa 44 44 44

Boost pressure mmHg 330 330 330

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)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
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T1=AF90 BCL=1.6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=54mm
----------
a=33deg+-3deg b=40deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At rack position aa, set the stopper screw. (2)At pump speed bb and rack position cc, set the stopper screw. (After setting, apply red paint.) (3)Use the hole above R = dd
----------
aa=19.3mm bb=0r/min cc=2.9+-0.3mm dd=35mm
----------
a=20deg+-5deg b=34deg+-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)-
----------
aa=6.4+-0.03mm
----------
a=(45deg)

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 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=1075r/min Ra=R1+0.3mm
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