108922-2140 ZEXEL 9 400 611 370 BOSCH INJECTION-PUMP ASSEMBLY 9400611370 1089222140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 370 9400611370

ZEXEL 108922-2140 1089222140

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Service parts 108922-2140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108092-0210

3. GOVERNOR 105960-0170

4. SUPPLY PUMP 105237-0230

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0990

7. COUPLING PLATE

8. _ 159640-0920

9. _ 156640-0520

10. NOZZLE AND HOLDER ASSY 105110-7920

11. Nozzle and Holder ME072662

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105041-4290

14. NOZZLE

15. NOZZLE SET 105019-2410

Include in #1:

108922-2140 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 370 9400611370

ZEXEL 108922-2140 1089222140

Zexel num

Bosch num

Firm num

Name

108922-2140
108922-2141

9 400 611 370

INJECTION-PUMP ASSEMBLY
10M21 * K 14CR TICS HD-TI10F 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 131424-8020

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. 52

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-8- 5-6-3-4- 9-10

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. 72 71.75 72.25

Difference between angles 3
Cal 1-8 deg. 117 116.75 117.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-6 deg. 189 188.75 189.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-4 deg. 261 260.75 261.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cal 1-10 deg. 333 332.75 333.25

Injection quantity adjustment

Rack position (12.1)

PWM % 56

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 150.5 149.5 151.5

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_02

Rack position (6.9)

PWM % 26.9+-2. 8

Pump speed r/min 380 380 380

Average injection quantity mm3/st. 19 17 21

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

0000001201

Pre-stroke mm 8.5 8.47 8.53

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 4.5 4.45 4.55

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 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

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
----------
aa=20mm bb=1mm
----------
a=19deg+-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.: aa (7)Pre-stroke: bb
----------
aa=0deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)

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.
----------

----------

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

Information:

Illustration 21 shows the direction the rack moves when the fuel injector is receiving fuel.
Illustration 22 g01455811
Illustration 1 - Flowchart for the Air in Fuel Test (Test F)
Illustration 23 g01455812
Illustration 2 - Flowchart for the Air in Fuel Test (Test F)Fuel Injector Cranking Test (Test G)
Note: The fuel injector cranking test checks for worn out injectors by measuring the cranking rack.
Illustration 24 g01412134
(3) The rack control (4) The number one fuel injectorNote: Refer to Illustration 24 for the location of the rack control and the location of the number one injector.
Illustration 25 g01412115
Flowchart for the Fuel Injector Cranking Test (Test G)Fuel Shutoff Solenoid Test (Test H)
Note: The fuel shutoff solenoid test determines if the fuel shutoff solenoid and wiring harness are operating properly.
Illustration 26 g01412143
Flowchart for the Fuel Shutoff Solenoid Test (Test H)Fuel Ratio Control (FRC) Setting Test (Test I)
Note: The FRC setting test checks the FRC setting.
Illustration 27 g01412145
Flowchart for the Fuel Ratio Control (FRC) Setting Test (Test I)Governor Servo Retaining Ring Test (Test J)
Note: Do not run the engine during this test.Note: The governor servo retaining ring test checks for faulty internal parts of the governor.
Illustration 28 g01422811
(1) Paddle
Illustration 29 g01422821
(2) Clevis pin
Illustration 30 g01412147
Flowchart for the Governor Servo Retaining Ring Test (Test J)Fuel Transfer Pump Test (Test K)
Note: The fuel transfer pump test is a visual inspection of the fuel transfer pump components.
Illustration 31 g01412150
(1) Screen (2) Inlet check valve (3) Spring (4) Bolt (5) Piston (6) Outlet check valve (7) Freeze plug (8) Piston check valve (9) Passage (10) Tappet Assembly (11) CamNote: Refer to Illustration 31 for the location of the components for the fuel transfer pump.
Illustration 32 g01412149
Flowchart for the Fuel Transfer Pump Test (Test K)Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)
Note: The FRC diaphragm leak test checks for a leaking FRC diaphragm.
Illustration 33 g01412154
Flowchart for the Fuel Ratio Control (FRC) Diaphragm Leak Test (Test L)