108822-3311 ZEXEL 9 400 611 974 BOSCH INJECTION-PUMP ASSEMBLY 9400611974 1088223311


 

Information injection-pump assembly

BOSCH 9 400 611 974 9400611974
ZEXEL 108822-3311 1088223311
108822-3311 INJECTION-PUMP ASSEMBLY
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Service parts 108822-3311 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108082-3751
3. GOVERNOR 105960-0251
4. SUPPLY PUMP 105237-0250
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2180
7. COUPLING PLATE
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:

108822-3311 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 974 9400611974
ZEXEL 108822-3311 1088223311


Zexel num
Bosch num
Firm num
Name
108822-3311 
108822-3312 
9 400 611 974 
   
INJECTION-PUMP ASSEMBLY
* K 14CQ TICS HD-TI8F 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   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   (12.1)
PWM %   56.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   134 132 136
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

Test data 108822-3311
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=0deg+-5deg b=37deg+-5deg

0000000901

Test data 108822-3311
(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
----------
aa=6.4+-0.03mm
----------
a=(80deg)

0000001501

Test data 108822-3311
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 108822-3311
(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 %
----------




Information:


Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples.A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken.Always use a separate pump for oil sampling and a separate pump for coolant sampling.Failure to do so may cause a false analysis which could lead to customer and dealer concerns.
New Systems, Refilled Systems, and Converted Systems
Perform an S O S coolant analysis (Level 2) at the following maintenance intervals.
Initial 500 service hours
Every Year or every 2000 hours, whichever comes firstPerform this analysis at the interval that occurs first for new systems, for refilled systems, or for converted systems that use Cat ELC (Extended Life Coolant) or use Cat DEAC (Diesel Engine Antifreeze/Coolant). This 500 hour check will also check for any residual cleaner that may have contaminated the system.Recommended Interval for S O S Services Coolant Sample
The following table contains the recommended sampling interval for all coolants that meet Cat EC-1 (Engine Coolant specification - 1). This is also the recommended sampling interval for all conventional heavy-duty coolant/antifreeze.The Level 2 Coolant Analysis should be performed if a problem is suspected or identified.
Table 1
Recommended Interval
Type of Coolant Level 1 Level 2
Cat DEAC
and Conventional Heavy-Duty Coolants Every 250 hours Yearly
Cat ELC
and Commercial EC-1 coolants Optional or every 500 hours Yearly or every 500 hours Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first.Refer to your machine OMM for recommendations specific to your machine.S O S Services Coolant Analysis (Level 1)
A coolant analysis (Level 1) is a test of the properties of the coolant.The following properties of the coolant are tested:
Glycol concentration for freeze protection and boil protection
Ability to protect from erosion and corrosion
pH
Conductivity
Visual analysis
Odor analysisThe results are reported, and appropriate recommendations are made.S O S Services Coolant Analysis (Level 2)
A coolant analysis ( Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system.The S O S coolant analysis ( Level 2) has the following features:
Full coolant analysis (Level 1)
Identification of metal corrosion and of contaminants
Identification of buildup of the impurities that cause corrosion
Identification of buildup of the impurities that cause scaling
Determination of the possibility of electrolysis within the cooling system of the engineThe results are reported, and appropriate recommendations are made.For more information on S O S coolant analysis, consult your Caterpillar dealer.

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