107692-1330 ZEXEL 9 400 611 802 BOSCH INJECTION-PUMP ASSEMBLY 9400611802 1076921330 8943920070

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 802 9400611802

ZEXEL 107692-1330 1076921330

ISUZU 8943920070 8943920070

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Buy INJECTION-PUMP ASSEMBLY 107692-1330 zexel genuine, new aftermarket engine parts with delivery

Service parts 107692-1330 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0310

3. GOVERNOR 105933-0840

4. SUPPLY PUMP 105237-6430

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2011

7. COUPLING PLATE 156638-6720

8. _ 159600-9421

9. _

10. NOZZLE AND HOLDER ASSY 105118-5817

11. Nozzle and Holder 8-94394-606-5

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3915

14. NOZZLE 105017-9000

15. NOZZLE SET

Include in #1:

107692-1330 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 802 9400611802

ZEXEL 107692-1330 1076921330

ISUZU 8943920070 8943920070

Zexel num

Bosch num

Firm num

Name

107692-1330

9 400 611 802

8943920070 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-TCS K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

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. 407980-2 24*

Digi switch no. 17

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 5.1 5.07 5.13

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 14.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 120 118.4 121.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 19 17.7 20.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

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(14.4)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 120 119 121

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-2.7

Boost pressure kPa 17.3 16 18.6

Boost pressure mmHg 130 120 140

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-0. 55)

Boost pressure kPa 48 48 48

Boost pressure mmHg 360 360 360

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.1 5.07 5.13

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

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
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T1=AB47 BCL=2.7+-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=35mm
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a=31.5deg+-5deg b=32.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
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aa=40mm bb=0r/min cc=1.5+-0.3mm
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a=44deg+-5deg b=12deg+-5deg

0000001301

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
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aa=1deg bb=5.1+-0.03mm
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a=(50deg)

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.
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0000001701

A : Stopper pin B: Connector
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0000001801

C:Shim
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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 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(14.4)+2.65mm N1=1250r/min V1=3+-0.01V
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Information:

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with this maintenance interval, perform previous maintenance intervals and Daily maintenance requirements. Perform the maintenance at the interval listed in the Maintenance Schedule for your engine.
For maintenance of the following components in this interval, refer to the OEM manual for maintenance instructions. The following are basic suggestions and instructions.
Marine Gear
Drain Oil
With the oil warm and the engine stopped, drain the transmission.1. Remove the transmission drain plug and allow the oil to drain. Obtain an oil sample for analysis.2. Clean and install the drain plug.If a Sump Pump is Used to Drain Oil
a. Connect a drain line and container to top outlet (A) of pump.b. Be sure valve (B) on the engine oil pan line is closed. Marks on the valve must be turned at right angles to the direction of the engine oil line. c. Open valve (C) on the transmission oil line. The marks on this valve must be turned so that one mark points to the pump and the second mark points to the transmission.d. Operate the sump pump (D) handle until the transmission is empty.e. Close the sump pump valve on the oil line to the transmission.Change Filters
1. Remove transmission oil filter housing drain plug (if equipped). Allow the oil to drain into the marine gear transmission sump.2. Remove filter assembly. Disassemble and discard the element.3. Clean the filter housing and assembly parts with clean, nonflammable solvent. Clean and install the filter housing drain plug.4. Inspect any retainer plates and/or seals. Install new seals if necessary.5. Assemble and install a new filter element assembly. Tighten all bolts.6. Operate the sump pump handle until the transmission is empty. Close the sump pump valve on the oil line to the transmission.Clean the Oil Strainer
1. Remove the strainer cover and plug. Remove the spring washer, strainer screen and magnetic screen tube (if equipped).2. Wash the strainer and magnetic screen tube with clean, nonflammable solvent. If a magnet is broken, install the new magnet properly. The North (N) poles and South (S) poles of the magnets are adjacent to each other so that they repel instead of attract: S-N, N-S, S-N.3. Inspect the strainer, plug and the cover seal for damage. Use new parts if used ones are damaged.4. Install the magnetic screen tube, strainer, spring washer, seal, cover and plug.Clean the Breather (All Marine Transmissions)
1. Remove the breather.2. Clean the breather with clean, nonflammable solvent.3. Install the breather.Fill the Transmission
Be sure both sump pump valves (one to the transmission and one to the engine oil pan) are closed. Otherwise a transfer of oil may occur during sump pump operation and damage could result.
1. Be sure the marine gear drain plug has been installed, or the sump pump valve (C) on the oil line to the marine gear drain line has been closed.2. Fill the marine gear to the FULL mark on the