108622-4031 ZEXEL 9 400 612 515 BOSCH INJECTION-PUMP ASSEMBLY 9400612515 1086224031


108622-4031 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 515 9400612515
ZEXEL 108622-4031 1086224031

Service parts 108622-4031 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
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:

108622-4031 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 515 9400612515
ZEXEL 108622-4031 1086224031


Zexel num
Bosch num
Firm num
Name
108622-4031 
9 400 612 515 
  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   14.35
Pump speed r/min   630 630 630
Average injection quantity mm3/st.   135 132 138
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(14.35 )
Pump speed r/min   630 630 630
Average injection quantity mm3/st.   135 133 137
Basic   *
Fixing the lever   *
Boost pressure kPa   75.3 75.3
Boost pressure mmHg   565 565
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.   123 117 129
Fixing the lever   *
Boost pressure kPa   75.3 75.3
Boost pressure mmHg   565 565
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   R2-2.5
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   62 62 62
Boost pressure mmHg   465 465 465
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

Test data 108622-4031
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=2.5+-0.1mm
----------

Speed control lever angle

Test data 108622-4031
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

Test data 108622-4031
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

Test data 108622-4031
(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

Test data 108622-4031
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

Test data 108622-4031
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(14.35)+0.9)mm N1=1050r/min V1=3+-0.01V
----------




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Group cross 108622-4031 ZEXEL

Daewoo 

 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY
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9 400 611 925 
 
INJECTION-PUMP ASSEMBLY
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9 400 612 057 
 
INJECTION-PUMP ASSEMBLY
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9 400 612 323 
 
INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
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9 400 612 091 
 
INJECTION-PUMP ASSEMBLY
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9 400 612 514 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
9 400 612 092 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
108622-4031  
9 400 612 515 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
9 400 612 058 
 
INJECTION-PUMP ASSEMBLY
9 400 612 186 
 
INJECTION-PUMP ASSEMBLY
9 400 612 645 
 
INJECTION-PUMP ASSEMBLY

Hyundai 

9 400 613 457 
3310083402 
INJECTION-PUMP ASSEMBLY
Q
F 01G 09U 0J3 
 
INJECTION-PUMP ASSEMBLY
9 400 612 093 
 
INJECTION-PUMP ASSEMBLY
9 400 612 187 
 
INJECTION-PUMP ASSEMBLY
9 400 612 348 
 
INJECTION-PUMP ASSEMBLY

Hyundai 

9 400 619 215 
3310083302 
INJECTION-PUMP ASSEMBLY
Q

Daewoo 

9 400 619 216 
65.111017339 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY

Daewoo 

9 400 612 516 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY
DE12TIS
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Hyundai 

9 400 619 217 
3310083450 
INJECTION-PUMP ASSEMBLY
Q
 
 
INJECTION-PUMP ASSEMBLY

Hyundai 

9 400 619 218 
3310083310 
INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
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