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


108622-3750 INJECTION-PUMP ASSEMBLY
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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
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

Test data 108622-3750
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
----------
T1=AF90 BCL=1.6+-0.1mm
----------

Speed control lever angle

Test data 108622-3750
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=54mm
----------
a=33deg+-3deg b=40deg+-5deg

Stop lever angle

Test data 108622-3750
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

Test data 108622-3750
(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

Test data 108622-3750
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

Test data 108622-3750
(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)
----------
L=33.5+-0.1mm N1=1075r/min Ra=R1+0.3mm
----------




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INJECTION-PUMP ASSEMBLY

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