108622-4040 ZEXEL 9 400 612 058 BOSCH INJECTION-PUMP ASSEMBLY 9400612058 1086224040

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 058 9400612058

ZEXEL 108622-4040 1086224040

Service parts 108622-4040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-4000

3. GOVERNOR 105923-4920

4. SUPPLY PUMP 105237-4840

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2580

7. COUPLING PLATE 156643-4520

8. _ 159601-7520

9. _

10. NOZZLE AND HOLDER ASSY 105110-8150

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/24.5{250}

13. NOZZLE-HOLDER 105041-4350

14. NOZZLE

15. NOZZLE SET 105019-2690

Include in #1:

108622-4040 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 058 9400612058

ZEXEL 108622-4040 1086224040

Zexel num

Bosch num

Firm num

Name

108622-4040
108622-4041

9 400 612 058

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 131424-8020

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 1-5-3-6- 2-4

Pre-stroke mm 6.4 6.37 6.43

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 16.1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 206 204 208

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 8.5+-0.5

Pump speed r/min 310 310 310

Average injection quantity mm3/st. 20 18 22

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(16.1)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 206 204 208

Basic *

Fixing the lever *

Boost pressure kPa 82.6 82.6

Boost pressure mmHg 620 620

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+0.5) +0.05-0. 1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 170 164 176

Fixing the lever *

Boost pressure kPa 82.6 82.6

Boost pressure mmHg 620 620

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 R2-3.7

Boost pressure kPa 13.3 12 14.6

Boost pressure mmHg 100 90 110

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-0. 6)

Boost pressure kPa 69.3 69.3 69.3

Boost pressure mmHg 520 520 520

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)Microswitch adjustment unnecessary. (4)Boost compensator stroke: BCL (5)Damper spring setting
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T1=AG84 BCL=3.7+-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=37.5mm
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a=2deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (2)Set the stopper screw. (3)Use the hole above R = cc
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aa=1200r/min bb=3.5+-0.3mm cc=25mm
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a=29.5deg+-5deg b=40deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=14deg bb=6.4+-0.03mm
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a=(7deg)

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 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=1000r/min Ra=(R1+0.5)+0.05-0.1mm
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