108622-4011 ZEXEL test values diesel fuel-injection equipment 27/05/24 11:16:44 Page 1

ZEXEL Ass'y No. 108622-4011

Bosch Ass'y No. 9 400 612 323
Bosch Typecode
Engine Type DE12TIS
Manufacturer DAEWOO
Edition date 11/11/04 (3)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113 or {SAEJ96
7d}
1404 Test oil
P 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
P Opening pressure MPa 20.7
P Opening pressure kgf/cm2 211
Injection pipe mm 8-3-600
Outer diameter - inner diameter - length (mm)
Overflow valve 134424-4120
P Overflow valve opening pressure kPa 255 221 289
P Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95
P Tester oil delivery pressure kPa 255 255 255
P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6
P PS/ACT control unit part no. 407980-224*
P Digi switch no. 31
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Direction of rotation (viewed from drive side) R
Right
P Injection order 1-5-3-6-2-4
S Pre-stroke mm 6.4 6.37 6.43
P Beginning of injection position NO.1
Governor side
S Difference between angles 1 deg. 60 59.75 60.25
Cal 1-5
S Difference between angles 2 deg. 120 119.75 120.25
Cal 1-3
S Difference between angles 3 deg. 180 179.75 180.25
Cal 1-6
S Difference between angles 4 deg. 240 239.75 240.25
Cyl.1-2
S Difference between angles 5 deg. 300 299.75 300.25
Cal 1-4
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 15.7
P Pump speed r/min 630 630 630
S Average injection quantity mm3/st. 166.5 163.5 169.5
S Max. variation between cylinders % 0 -2 2
P Basic *
P Fixing the rack *
P PS407980-224* V 2.45+-0.01
P PS407980-224* mm 4+-0.05
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point Z
P Rack position 8.9+-0.5
P Pump speed r/min 445 445 445
S Average injection quantity mm3/st. 13.5 12 15

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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S Max. variation between cylinders % 0 -15 15

P Fixing the rack *
P PS407980-224* V V1+0.05+-0.01
P PS407980-224* mm 6.3+-0.03
P Standard for adjustment of the maximum vari *
ation between cylinders
Remarks
Refer to items regarding the pre-stroke actuator
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position R1(15.7)
P Pump speed r/min 630 630 630
S Average injection quantity mm3/st. 166.5 164.5 168.5
P Basic *
P Fixing the lever *
P Boost pressure kPa 109 109
P Boost pressure mmHg 820 820
P PS407980-224* V 2.45+-0.01
P PS407980-224* mm 4+-0.05
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point B
P Rack position (R1+0.9)
P Pump speed r/min 1050 1050 1050
S Average injection quantity mm3/st. 143.5 137.5 149.5
P Fixing the lever *
P Boost pressure kPa 109 109
P Boost pressure mmHg 820 820
P PS407980-224* V 2.45+-0.01
P PS407980-224* mm 4+-0.05

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.3 Governor adjustment

Name

T1=AG98 N:Pump speed

BCL=3.85+-0.1mm 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
2.4 Boost compensator adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 250 250 250
P Rack position R2-3.85
S Boost pressure kPa 10.7 9.4 12
S Boost pressure mmHg 80 70 90
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 250 250 250
P Rack position R2(R1+0.15)
S Boost pressure kPa 96 96 96
About
S Boost pressure mmHg 720 720 720
About

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.5 Speed control lever angle

Name
a=10.5deg+-5deg
b=38deg+-3deg

aa=70.3mm F:Full speed

I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
2.6 Stop lever angle
Name
a=44deg+-5deg
b=20deg+-5deg

aa=40mm N:Pump normal

bb=0r/min S:Stop the pump.
cc=1.5+-0.3mm (1)Use the hole at R = aa
(2)Speed = bb, rack position = cc
(3)Set the stopper screw. (After setting, apply red paint.)

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.7 Timing setting

Name
a=(70deg)

aa=6.4+-0.03mm (1)Pump vertical direction

(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
2.8 Pre-stroke actuator adjustment
2.8.1 Adjustment value
CAT Designation Unit Set value min. max. Actual values OT
S Pre-stroke mm 6.4 6.37 6.43
Remarks
When the timing sleeve is pushed up
CAT Designation Unit Set value min. max. Actual values OT
P Connector angle deg. 8.5 8 9
Remarks
When the eccentric pin is tightened
CAT Designation Unit Set value min. max. Actual values OT
P Supply voltage V 24 23.5 24.5
P Ambient temperature degC 23 18 28
P Pre-stroke mm 4 3.95 4.05
S Output voltage V 2.45 2.44 2.46
P Adjustment *
CAT Designation Unit Set value min. max. Actual values OT
P Supply voltage V 24 23.5 24.5
P Ambient temperature degC 23 18 28
P Pre-stroke mm 6.4 6.37 6.43
S Output voltage V 1.2 1 1.4
P Confirmation *
Remarks
Output voltage V1
CAT Designation Unit Set value min. max. Actual values OT
P Supply voltage V 24 23.5 24.5
P Ambient temperature degC 23 18 28
S Pre-stroke mm 3.4 3.4
P Output voltage V 3 2.98 3
P Confirmation *
CAT Designation Unit Set value min. max. Actual values OT
P Supply voltage V 24 23.5 24.5
P Ambient temperature degC 23 18 28
S Output voltage V 3.05 3.05
P Confirmation of operating range *

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.8.2 Adjusting method and stamping position

Name

A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, t
hen 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 tha
t 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 a
nd housing side.
2.9 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.9.1 Additional device 1

Name RACK SENSOR

Ra=(R1(15.7)+0.9)mm G:Red paint

N1=1050r/min H:Pump end face
V1=3+-0.01V 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)

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)