108822-3304 ZEXEL 9 400 611 927 BOSCH INJECTION-PUMP ASSEMBLY 9400611927 1088223304

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 927 9400611927

ZEXEL 108822-3304 1088223304

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Service parts 108822-3304 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3751

3. GOVERNOR 105960-0122

4. SUPPLY PUMP 105237-0250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2180

7. COUPLING PLATE

8. _ 159640-0620

9. _ 156640-3121

10. NOZZLE AND HOLDER ASSY 105101-8561

11. Nozzle and Holder 23600-3342A

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105030-3730

14. NOZZLE

15. NOZZLE SET 105019-2500

Include in #1:

108822-3304 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 927 9400611927

ZEXEL 108822-3304 1088223304

Zexel num

Bosch num

Firm num

Name

108822-3304
108822-3305

9 400 611 927

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 134424-4120

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

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 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
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (13.1)

PWM % 62

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 156.5 154.5 158.5

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Rack position (6.6)

PWM % 25.3+-2. 8

Pump speed r/min 380 380 380

Average injection quantity mm3/st. 16 15 17

Max. variation between cylinders % 0 -10 10

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

0000001201

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:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg

0000000901

(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.:- (7)Pre-stroke: aa
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aa=6.4+-0.03mm
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a=(80deg)

0000001501

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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0000001701

(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.
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a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
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Information:

Introduction
This Special Instruction is intended for the installation of the 366-9748 Injector Wiring Harness Kit . The 366-9748 Injector Wiring Harness Kit can be used to repair TPI connectors. TPI connectors can be found on HEUI injectors, variable valve actuators, and Cat Brakes.Removal of the Connector From the Wire Harness
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9150 Terminal Crimp Tool As 1
B 9U-6070
or Heat Gun Gp
(110V) 1
9U-6072 Heat Gun Gp (220 V) The following steps will remove the connector for an injector from the wire harness that is under the valve mechanism cover.
Illustration 1 g01035448
(1) Side "A" of the connector (2) Side "B" of the connectorNote: Side "A" or side "1" of the connector is the output signal wire from the ECM. Side"B" or side "2" of the connector is the sensor return.
Identify side "A" of the connector and identify side "B" of the connector.
Mark each wire on the wire harness before the wires are cut. Most connectors will have the label of an "A" and a "B". Some connectors may have a "1" and a "2" that is on the connector. The label with a "1" will be an "A". The label with a "2" will be a "B".
Illustration 2 g01034438
Connector that is cut from the wire harness (3) Wire on side "A" of the connector (4) Wire on side "B" of the connector
Cut wire (3) at a distance of 45 mm (1.8 inch).
Cut wire (4) at a distance of 40 mm (1.6 inch).
Illustration 3 g01034450
(5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connectorNote: The wires on the old connector are cut to length so that the wires on the wire harness to the new connector will match up. The proper length will help in matching the harness wires to the wires on the new connector wires.
Discard the connector.Installation Procedure for the Connector
Use Tool (A) to strip the plastic off wires (5) and (6) at a distance of 5 mm (0.19 inch).
Illustration 4 g01034451
Connecting the connector to the wire harness (5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector (7) Heat shrink tube (8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use the heat shrink tubes from 366-9748 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.
Take wire (5) and slide wire (5) in the butt splice (8).
Take wire (6) and slide wire (6) in the butt splice (9).
Illustration 5 g01035814
Illustration 6 g01034452
(8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use Tool