108622-4001 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086224001

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108622-4001 1086224001

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Service parts 108622-4001 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3840

3. GOVERNOR 105923-4160

4. SUPPLY PUMP 105237-5360

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2490

7. COUPLING PLATE 156639-9720

8. _ 159601-4120

9. _

10. NOZZLE AND HOLDER ASSY 105101-8460

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105030-4711

14. NOZZLE

105025-2240

15. NOZZLE SET

Include in #1:

108622-4001 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108622-4001 1086224001

Zexel num

Bosch num

Firm num

Name

108622-4001
108622-4002

DAEWOO

INJECTION-PUMP ASSEMBLY
DE12TIS *

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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 31

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 6.4 6.37 6.43

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 15.2

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 154.5 151.5 157.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

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 425 425 425

Average injection quantity mm3/st. 13 11.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-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(15.2)

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 154.5 152.5 156.5

Basic *

Fixing the lever *

Boost pressure kPa 105 105

Boost pressure mmHg 785 785

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+1.5)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 143.5 137.5 149.5

Fixing the lever *

Boost pressure kPa 105 105

Boost pressure mmHg 785 785

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-3.8

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1+0. 45)

Boost pressure kPa 91.3 91.3 91.3

Boost pressure mmHg 685 685 685

0000001601

Pre-stroke mm 6.4 6.37 6.43

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 4 3.95 4.05

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 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

Pre-stroke mm 3.4

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)Microswitch adjustment unnecessary (deliver with adjusting bolt fully backed off). (4)Boost compensator stroke: BCL (5)Damper spring setting
----------
T1=AG38 BCL=3.8+-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'
----------
aa=70.3mm
----------
a=14deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper screw so that speed = bb, rack position = cc (after setting apply red paint).
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=44deg+-5deg b=20deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=6.4+-0.03mm
----------
a=(70deg)

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.
----------

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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(15.2)+1.5)mm N1=1050r/min V1=3+-0.01V
----------

Information:

a) Remove by screwing flywheel attaching bolts uniformly into the bolt holes for removal. Pull out using the special tool, Gear Puller. Do not remove the gear by striking it. b) Heat the gear to about 100°C by a heater, etc. Aligning the crankshaft dowel pin with the dowel pin hole in the gear, insert the shaft into the gear, lightly striking the gear end face with a soft hammer.c) Install the sleeve using the special tool, Oil Seal and Sleeve Installer. [Refer to Item (2) - (b), Section 5.1.3.](3) Reassembly Reassembly
(a) Installation of oil jet (excluding 6D14, 6D15) Fix the oil jet aligning with the locating pin and tighten the check valve to specified torque. Bend lock washer onto the check valve to prevent it from turning.(b) Installation of thrust plate and main bearing 1. Install the thrust plate with its side having no oil groove toward the crankcase.2. Line up the lug of main bearing with the lug groove in crankcase. Note that the upper main bearing has an oil hole, which must not be confused with the lower bearing.3. Apply engine oil to all sliding surfaces.(c) Installation of main bearing cap 1) Fit the lower main bearing into the main bearing cap. At the time, make sure that the main bearing lug is aligned with the main bearing cap lug groove.2) Install also the thrust plate onto the main bearing cap in the rear-end position.3) Make sure that the main bearing cap lug groove and crankcase lug groove are on the same side. 1. Face the side of thrust plate having no oil groove toward the rear end of the crankcase and toward the main bearing cap.2. Use thrust plates of the same size for the rear end of the crankcase and main bearing cap rear end. 4) Tighten the main bearing cap bolt to specification. Then, make sure that the crankshaft turns smoothly by hand.5) Measure the crankshaft end play to determine if it is within the nominal value [Refer to Item (1) - (c), Section 5.1.4.].(d) Reassembly of piston and connecting rod 1) Assemble the piston and the connecting rod, ensuring correct direction as illustrated.2) Insert the piston pin to couple the piston and connecting rod. Mount the snap ring to hold the piston pin in position. The piston pin is a clearance fit in the piston. If the piston pin is hard to fit, heat the piston with a piston heater or hot water. 1. Keep the piston weight difference for one engine within 10 g.2. Use connecting rod assembly of same weight mark for an engine.3. Check to see that the size mark of the piston is same as that of the cylinder liner.4. Apply engine oil to sliding surfaces. 3) The connecting rod bolts do not normally need removal; however, where replacement is necessary for damaged bolt, install new bolts by using the following procedures. Make sure that the connecting rod bolt hole is free from damage and burrs. Then,