108622-4082 ZEXEL 9 400 619 217 BOSCH INJECTION-PUMP ASSEMBLY 9400619217 1086224082 3310083450


108622-4082 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 217 9400619217
ZEXEL 108622-4082 1086224082
HYUNDAI 3310083450 3310083450

Service parts 108622-4082 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-4001
3. GOVERNOR 105923-4922
4. SUPPLY PUMP 105237-4840
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2590
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-8150
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1(185)/24.5(250)
13. NOZZLE-HOLDER 105041-4350
14. NOZZLE
15. NOZZLE SET 105019-2690

Include in #1:

108622-4082 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 217 9400619217
ZEXEL 108622-4082 1086224082
HYUNDAI 3310083450 3310083450


Zexel num
Bosch num
Firm num
Name
108622-4082 
9 400 619 217 
3310083450  HYUNDAI
INJECTION-PUMP ASSEMBLY
Q K

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
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   33
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   15.1
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   176.5 174.5 178.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the rack   *
PS407980-224* V   2.2+-0.0 1
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   310 310 310
Average injection quantity mm3/st.   20 18 22
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(15.1)
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   176.5 174.5 178.5
Basic   *
Fixing the lever   *
Boost pressure kPa   70.6 70.6
Boost pressure mmHg   530 530
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Injection quantity adjustment_04
Adjusting point   B
Rack position   (R1+0.5) +0.05-0. 1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   143.5 137.5 149.5
Fixing the lever   *
Boost pressure kPa   70.6 70.6
Boost pressure mmHg   530 530
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-2.7
Boost pressure kPa   13.3 12 14.6
Boost pressure mmHg   100 90 110
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-0. 6)
Boost pressure kPa   57.3 57.3 57.3
Boost pressure mmHg   430 430 430
0000001601
Pre-stroke mm   6.4 6.37 6.43
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   2.4 2.35 2.45
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   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
Output voltage V   3.05 3.05
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 108622-4082
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
----------
T1=AG96 BCL=2.7+-0.1mm
----------

Speed control lever angle

Test data 108622-4082
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=37.5mm
----------
a=2deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 108622-4082
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper screw at speed = bb and rack position = cd.
----------
aa=25mm bb=1200r/min cc=3.5+-0.3mm
----------
a=29.5deg+-5deg b=40deg+-5deg

0000001301

Test data 108622-4082
(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=(0deg)

0000001901

Test data 108622-4082
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 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=9+-0.1mm
----------

0000002301 RACK SENSOR

Test data 108622-4082
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1000r/min Ra=(R1+0.5)+0.05-0.1mm
----------




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