107691-2291 ZEXEL 9 400 618 903 BOSCH INJECTION-PUMP ASSEMBLY 9400618903 1076912291

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 903 9400618903

ZEXEL 107691-2291 1076912291

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Cross reference number

BOSCH 9 400 618 903 9400618903

ZEXEL 107691-2291 1076912291

Zexel num

Bosch num

Firm num

Name

107691-2291
107691-2292

9 400 618 903

INJECTION-PUMP ASSEMBLY
6D16T4 * 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 131425-0520

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. 407910-3 03*

Selector switch no. 03

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

Digi switch no. 16

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 5.6 5.57 5.63

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 11.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 106.5 104.9 108.1

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.6+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.5+-0.5

Pump speed r/min 520 520 520

Average injection quantity mm3/st. 10 8.2 11.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

PS407910-303* V V1-0.05+ -0.01

PS407910-303* mm 5.5+-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(11.8)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 106.5 105.5 107.5

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.3

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 123 119 127

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.6+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.7

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 25)

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min 1075

Advance angle deg. -1.5 -2 -1

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 1.17 1.16 1.18

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 2.8 2.6 3

Confirmation *

Remarks
Output voltage V1

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 0.95

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
----------
T1=AC41 BCL=0.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=39deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=1300r/min cc=1.5+-0.3mm
----------
a=6deg+-5deg b=45deg+-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=8deg bb=5.6+-0.03mm
----------
a=(3deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

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 clockwise (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 counterclockwise 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 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

0000002301 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)
----------
N1=1300r/min Ra=R1(11.8)+2.3mm
----------

Information:

Problem
The fuel injectors may fail on certain Challenger 75 Tractors and 3176 Truck Engines.
Affected Product
Model & Identification Number
Challenger 75 (4CJ1-406)
3176 (2YG1-Up; 7LG1-4822)
Parts Needed
Use the following parts in quantities needed to perform repairs. The application of each injector listed is noted. Use remanufactured injectors, unless it is not available.
0R3397 Injector Grp. (4P9510 if remanufactured is not available for 7LG 250-300 HP)0R3398 Injector Grp. (4P9520 if remanufactured is not available for 7LG 325 HP and Challenger 75 4CJ1-406)0R3399 Injector Grp. (4P9610 if remanufactured is not available for 2YG 250-275 HP)0R3400 Injector Grp. (4P9620 if remanufactured is not available for 2YG 300-325 HP)9X7317 Seal (injector tip O-ring)9X7557 Seal (injector upper O-ring)9X7722 Seal (injector lower O-ring)336044 Seal (injector thrust-pad-retaining O-ring)Action Required
See attached Rework Procedure.
Service Claim Allowances
Challenger 75 Tractors
This is a 2.5-hour job. Add 0.2 hours for 1st injector diagnostic test and 0.1 hours for each additional injector test. Add 1.2 hours for first injector sleeve replaced and 0.7 hours for each additional sleeve replaced.
3176 Truck Engines
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
1. Isolate the problem to the individual injector causing the problem. For this program only the failed injector(s) is covered so it is important to isolate the individual injector(s) causing the problem.A. For fuel dilution of the engine oil, first attempt to find the leak by pressurizing the low pressure system with the hand priming pump and the return line blocked off. Visually inspect each injector for leaks. It is also important to inspect the cylinder head casting for leaks around the injector bore, in the hold down bolt holes and along the gallery which crosses the camshaft compartment. If no leaks are found the injectors should be removed and leak tested using the 1U6661 Pop Tester. Drain the fuel manifold by removing the lower plug at the rear of the manifold. Remove the suspect injector(s). Test the injector(s) with the 1U6661 Pop Tester following the procedures in Special Instructions SEHS8867. Be sure to activate the solenoid valve and stroke the injector to create high pressure inside the injector when inspecting the high pressure plug for leaks. The plug is located at the base of the forged body.
The leak-down rate is a measure of plunger clearance leakage and should be checked when looking for fuel leaks.
Some small amount of leakage at the terminal post is permitted. Refer to Service Magazine September 21, 1991 or Truck Engine News October 1991.
B. For misfire or performance problems identification of a failed injector may require duplication of the conditions where the complaint exists. Interviewing the driver for the load and speed conditions where the problem occurs will be helpful. Diagnosis of the problem may require driving the truck with a load on or using a chassis dynomometer if the complaint arises only under loaded conditions.First attempt to diagnose the problem on the engine. Use the ECAP Tool to cut out cylinders under conditions which duplicate the complaint. Noticeable differences in the sound, fuel position (rack),