108622-4030 ZEXEL 9 400 612 092 BOSCH INJECTION-PUMP ASSEMBLY 9400612092 1086224030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 092 9400612092

ZEXEL 108622-4030 1086224030

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Service parts 108622-4030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3960

3. GOVERNOR 105923-4830

4. SUPPLY PUMP 105237-5360

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-9720

8. _ 159601-4121

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

15. NOZZLE SET 105019-2250

Include in #1:

108622-4030 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 092 9400612092

ZEXEL 108622-4030 1086224030

Zexel num

Bosch num

Firm num

Name

108622-4030
108622-4031

9 400 612 092

DAEWOO

INJECTION-PUMP ASSEMBLY
DE12TIS * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SEAJ967d}

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 14.5

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 139 136 142

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 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(14.5)

Pump speed r/min 630 630 630

Average injection quantity mm3/st. 139 137 141

Basic *

Fixing the lever *

Boost pressure kPa 80 80

Boost pressure mmHg 600 600

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+1.25 )

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 131.5 125.5 137.5

Fixing the lever *

Boost pressure kPa 80 80

Boost pressure mmHg 600 600

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 270 270 270

Rack position R2-2.8

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 270 270 270

Rack position R2(R1+0. 2)

Boost pressure kPa 66.7 66.7 66.7

Boost pressure mmHg 500 500 500

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. (4)Boost compensator stroke: BCL (5)Damper spring setting
----------
T1=AG63 BCL=2.8+-0.1mm
----------

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=39deg+-3deg b=14deg+-5deg

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.
----------

----------

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(14.5)+1.25)mm N1=1050r/min V1=3+-0.01V
----------

Information:

Literature Information
This manual contains information and instructions concerning engine safety, operation, lubrication, and maintenance. Read, study, and keep it available with other literature and engine information.Some photographs or illustrations in this publication show details or attachments that may differ from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this publication.Whenever a question arises regarding your engine, or this publication, please consult your Caterpillar dealer for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and/or repair on this product.Operation
Engine operation outlined in this publication is basic. Engine operators gain knowledge of the engine through experience, developing operation skills and techniques which enhance efficient and economical engine operation.The operation section is a reference for operators. Photographs and illustrations guide operators through correct procedures of inspecting, starting, operating and stopping the engine. Discussion of gauges and engine control information is included.Maintenance
The maintenance section is a guide to engine care. The illustrated instructions are grouped by maintenance service intervals. The actual operating environment of the engine also governs the maintenance schedule. Under extremely severe, dusty, or frigid operating conditions, lubrication and maintenance checks more frequent than those specified in the Maintenance Schedule may be necessary. Maintenance Intervals
Use the service hour meter to determine service intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals, if they provide more convenient serving schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.We recommend that the maintenance schedules be reproduced for ease of inspection. We also recommend that ongoing maintenance records be kept to document engine service. See the Maintenance Records section of this publication for information regarding documents that are generally accepted as proof of maintenance or repair. Your Caterpillar dealer can assist you in tailoring your Maintenance Schedule to meet the needs of your operating environment.Overhaul
Major engine repair details are not covered in this manual. Major repairs are best left to trained personnel or an authorized Caterpillar dealer.If a major engine failure requiring removal of the engine occurs, numerous after-failure overhaul options available from your Caterpillar dealer. Contact your dealer for information regarding these options.Engine Description
The engines described in this publication are the 3408C and 3412C Industrial and EPG diesel engines.They are designed primarily for agricultural, prime power and standby electrical power generation, petroleum and auxiliary industrial applications.Engine Storage
For general information, refer to the Engine Lifting & Storage topic. For complete engine storage information refer to Special Instruction SEHS9031, Storage Procedure for Caterpillar Products.California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.