108622-4021 ZEXEL 9 400 612 514 BOSCH INJECTION-PUMP ASSEMBLY 9400612514 1086224021

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 514 9400612514

ZEXEL 108622-4021 1086224021

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Buy INJECTION-PUMP ASSEMBLY 108622-4021 zexel genuine, new aftermarket engine parts with delivery

Service parts 108622-4021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-4020

3. GOVERNOR 105923-4831

4. SUPPLY PUMP 105237-5360

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2490

7. COUPLING PLATE 156643-5120

8. _ 159601-7720

9. _

10. NOZZLE AND HOLDER ASSY 105101-8460

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER 105030-4711

14. NOZZLE

105025-2240

15. NOZZLE SET

Include in #1:

108622-4021 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 514 9400612514

ZEXEL 108622-4021 1086224021

Zexel num

Bosch num

Firm num

Name

108622-4021

9 400 612 514

DAEWOO

INJECTION-PUMP ASSEMBLY
DE12TIS K 14CJ INJECTION PUMP ASSY TICS HD-TI6M 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

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 14.85

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 145.5 142.5 148.5

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 8.9+-0.5

Pump speed r/min 445 445 445

Average injection quantity mm3/st. 13.5 12 15

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(14.85 )

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 145.5 143.5 147.5

Basic *

Fixing the lever *

Boost pressure kPa 86.6 86.6

Boost pressure mmHg 650 650

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+0.9)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 131.5 125.5 137.5

Fixing the lever *

Boost pressure kPa 86.6 86.6

Boost pressure mmHg 650 650

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 250 250 250

Rack position R2-3

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 250 250 250

Rack position R2(R1+0. 15)

Boost pressure kPa 73.3 73.3 73.3

Boost pressure mmHg 550 550 550

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)Boost compensator stroke: BCL (4)Damper spring setting (5)Microswitch adjustment unnecessary (deliver with adjusting bolt fully backed off).
----------
T1=AG98 BCL=3+-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=10.5deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (3)Set the stopper screw. (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(14.85)+0.9)mm N1=1050r/min V1=3+-0.01V
----------

Information:

3.1 Service Standards Table
3.2 Tightening torque table
4. Special Tool
5. Service Procedures
5.1 Removal and Installation
(1) Removal (a) When removing the pressure plate and lever assembly, fix the pressure plate using the special tools, Stopper Bolt and Washer. (C4 and C8 only) (b) Install the special tool, Clutch Alignment Arbor to prevent drop of the clutch disc and then remove the pressure plate and lever assembly.(2) Installation (a) Install the clutch disc using the special tool, Clutch Alignment Arbor. When installing the clutch disc, use care not to confuse the front and reverse sides. Install with the side bearing the part No. facing outside. (b) Install the pressure plate and lever assembly, aligning with the knock pins of the fly wheel. In the case of C4 and C8, install after fixing the pressure plate using special tools, Stopper Bolt and Washer. 1. Before installing the clutch, check and clean the flywheel. If faulty, correct or replace.2. When tightening the bolts, do so in diagonal order and uniformly.3. After installation, be sure to remove the Stopper Bolt and Washer. (C4 and C8 only)(c) Inspection of release lever plate height (at clutch disc replacement only) Using special tool, Clutch Release Lever Aligner, check the height of the clutch cover and release lever plate.If adjustment is necessary, adjust referring to 5.2.2 (3).(d) Adjustment after installation of bearing case. After installation, adjust the free travel (clearance between the release bearing and release lever). 1) Move the lever in the direction to engage the clutch. At a position where a click is heard in the clutch, turn the adjusting bolt A until it is blocked by the stopper, and lock it by turning down the bolt another two or three threads.2) From the position where the release bearing has touched the release lever, turn the adjusting screw B in the direction to disengage the clutch and check to see that the clutch is in disengaged position. Then lock the bolt. When making adjustment, lock in position the ratchet of the lever of the opposite side. 1) Loosen the control ling lock nut and from the position where the release bearing is in contact with the release lever, move back by B1 mm and lock in position (clutch lever setting position when clutch is engaged).2) In the direction to disengage the clutch, lock the air cylinder adjusting bolt at a position B2 mm from the position where the release bearing is in contact with the release lever.5.2 Clutch Proper
Disassembly and inspection
Disassembly and Inspection(1) Removal of clutch cover (a) Matchmark the clutch cover and pressure plate and using special tool, Clutch Installer, compress the pressure spring and remove support lever nut, strap bolt, etc.(b) Slowly loosen the handle of the Clutch Installer to remove the clutch cover.(2) Wear of facing Measure the depth from facing surface to rivet head. If the depth is smaller than the limit, replace the clutch disc assembly.(3) Runout of clutch disc Using a runout tester, measure the runout of the clutch