108822-1000 ZEXEL 9 400 611 486 BOSCH INJECTION-PUMP ASSEMBLY 9400611486 1088221000 1156031270


108822-1000 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 611 486 9400611486
ZEXEL 108822-1000 1088221000
ISUZU 1156031270 1156031270

Service parts 108822-1000 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108082-3690
3. GOVERNOR 105960-0040
4. SUPPLY PUMP 105237-0210
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-0860
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105110-7830
11. Nozzle and Holder 1-15300-345-0
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.1{225}
13. NOZZLE-HOLDER 105041-4270
14. NOZZLE
15. NOZZLE SET 105019-2330

Include in #1:

108822-1000 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 486 9400611486
ZEXEL 108822-1000 1088221000
ISUZU 1156031270 1156031270


Zexel num
Bosch num
Firm num
Name
108822-1000 
108822-1001 
9 400 611 486 
1156031270  ISUZU
INJECTION-PUMP ASSEMBLY
8TD1 * 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   131424-8120
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
RED4 control unit part number   407915-0 590
RED4 rack sensor specifications mm   19
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   41
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-8-7-3- 6-5-4-2
Pre-stroke mm   7.2 7.17 7.23
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-8
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-7
deg.   90 89.75 90.25
Difference between angles 3
Cal 1-3
deg.   135 134.75 135.25
Difference between angles 4
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 5
Cal 1-5
deg.   225 224.75 225.25
Difference between angles 6
Cal 1-4
deg.   270 269.75 270.25
Difference between angles 7
Cyl.1-2
deg.   315 314.75 315.25
Injection quantity adjustment
Rack position   (12.6)
PWM %   58.9
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   162 160 164
Max. variation between cylinders %   0 -3 3
Basic   *
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4.8+-0.0 5
Injection quantity adjustment_02
Rack position   (6.8)
PWM %   26.4+-2. 8
Pump speed r/min   315 315 315
Average injection quantity mm3/st.   20.5 17.3 23.7
Max. variation between cylinders %   0 -13 13
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   7.1+-0.0 3
Remarks
Refer to items regarding the pre-stroke actuator
 
0000001201
Pre-stroke mm   7.2 7.17 7.23
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   3.2 3.15 3.25
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   7.2 7.17 7.23
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:

Speed control lever angle

Test data 108822-1000
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=37deg+-5deg b=37deg+-5deg

0000000901

Test data 108822-1000
(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=1deg bb=7.2+-0.03mm
----------
a=(90deg)

0000001501

Test data 108822-1000
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.
----------

----------

0000001701

Test data 108822-1000
(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------




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Group cross 108822-1000 ZEXEL

Isuzu 

108822-1000  

108822-1001 
9 400 611 486 
1156031270 
INJECTION-PUMP ASSEMBLY
8TD1
9 400 611 184 
1156031271 
INJECTION-PUMP ASSEMBLY
8TD1
9 400 611 304 
 
INJECTION-PUMP ASSEMBLY

Isuzu 

 
1156031272 
INJECTION-PUMP ASSEMBLY
8TD1
9 400 611 970 
1156033800 
INJECTION-PUMP ASSEMBLY
8TD1
9 400 612 733 
1156033801 
INJECTION-PUMP ASSEMBLY
8TD1
9 400 612 964 
1156033802 
INJECTION-PUMP ASSEMBLY
8TD1
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