108822-2030 ZEXEL 9 400 619 790 BOSCH INJECTION-PUMP ASSEMBLY 9400619790 1088222030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 790 9400619790

ZEXEL 108822-2030 1088222030

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Buy INJECTION-PUMP ASSEMBLY 108822-2030 zexel genuine, new aftermarket engine parts with delivery

Service parts 108822-2030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3100

3. GOVERNOR 105923-0360

4. SUPPLY PUMP 105237-6100

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0990

7. COUPLING PLATE

8. _ 159590-8320

9. _ 156640-0420

10. NOZZLE AND HOLDER ASSY 105110-7382

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105041-4121

14. NOZZLE

15. NOZZLE SET 105019-0350

Include in #1:

108822-2030 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 790 9400619790

ZEXEL 108822-2030 1088222030

Zexel num

Bosch num

Firm num

Name

108822-2030
108822-2031

9 400 619 790

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 105780-8230

Nozzle 105780-0110

Nozzle holder 105780-2170

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0220

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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. 42

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 8.5 8.47 8.53

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 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 1-4 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 13.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 127 125.4 128.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

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 290 290 290

Average injection quantity mm3/st. 23.5 20.9 26.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-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(13.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 127 126 128

Basic *

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.55

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 129.5 125.5 133.5

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

0000001601

Pre-stroke mm 8.5 8.47 8.53

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

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 6.1 6.05 6.15

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 8.5 8.47 8.53

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

Pre-stroke mm 5.5

Output voltage V 3 2.98 3

Confirmation *

_06

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)Damper spring setting
----------
T1=AB07
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=30deg+-5deg b=(40deg)+-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.) (3)Normal engine position (equivalent to R = dd).
----------
aa=31.5mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=11.5deg+-5deg c=41deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove. (4)Damper (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
----------
aa=4deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)

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.
----------

----------

0000002201 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=8.5+-0.1mm
----------

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=1100r/min Ra=R1(13.3)+1.55mm
----------

Information:

Warning Operation
Two flashing warning lamps and an alarm inform the operator that: * An ether cylinder is empty.* Both ether cylinders are empty.* A noncritical fault is present.* A critical fault is present.The warning lamps and alarm can be tested by placing the ether system switch in the Test/Disable position. The warning alarm will turn ON for two seconds and the warning lamps will remain ON continuously until the switch is returned to the Auto position. If a solenoid valve is shorted to +BAT, the alarm sounds whenever the key switch is in the RUN or START position. The alarm beeps at the rate of approximately 1.3 seconds ON and 2.0 seconds OFF. The engine could be damaged if ether was injected before the engine is cranked.An Ether Cylinder Is Empty
One of the two warning lamps inform the operator when an ether cylinder is empty. The lamp flashes at the rate of 1.5 Hz (flashes per second) with equal ON and OFF times. The lamps and ether solenoid assemblies are correspondingly marked 1 and 2. When empty ether cylinder warning lamp 1 is flashing, ether cylinder 1 needs replaced. When empty ether cylinder warning lamp 2 is flashing, ether cylinder 2 needs replaced. (On 3516 engines, both ether cylinders of the set need replaced.) The lamps stop flashing when the reset switch is activated during ether cylinder replacement. The empty ether cylinder warning lamp will also flash if there is no ether cylinder installed.Both Ether Cylinders Are Empty
When both ether cylinders are empty (on 3516 engines, both ether cylinder sets), both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash at the same time, at the rate of 1.5 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF.A Noncritical Fault Is Present
When a noncritical fault is present, both empty ether cylinder warning lamps are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The system continues to operate during a noncritical fault.A Critical Fault Is Present
When a critical fault is present. both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF. If possible, ether injections are disabled during a critical fault.Diagnostic Operation
Ether Injection Control DiagnosticsThe ether injection control has diagnostic capabilities to assist in troubleshooting. The control detects and records faults that occur to the system. During a critical fault, if possible, the control disables ether injection. During a noncritical fault, the control takes alternate action so that the system continues to function.The diagnostic display, on the ether injection control, displays a code which represents the fault that