Rating:
Information injection-pump assembly
ZEXEL
108621-2020
1086212020
Service parts 108621-2020 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME060110
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
108621-2020
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108621-2020
1086212020
Zexel num
Bosch num
Firm num
Name
108621-2020
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-7220
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
21
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.2
Pump speed
r/min
650
650
650
Each cylinder's injection qty
mm3/st.
175.4
171
179.8
Basic
*
Fixing the rack
*
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.3+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
11.6
9.9
13.3
Fixing the rack
*
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.2)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
175.4
174.4
176.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
159.8
153.8
165.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Injection quantity adjustment_05
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
180
160
200
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2(R1-1.
6)
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(11.2)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
700--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
650
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
850
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
0000001601
Pre-stroke
mm
5.6
5.57
5.63
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
5
4.5
5.5
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1
1
1.05
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.6
2.32
2.88
Output voltage
V
2.8
2.73
2.87
Confirmation
*
_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
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Boost compensator cancel stroke: BSL
(3)Boost compensator stroke
(4)Damper spring setting
----------
BSL=1.8mm
----------
----------
BSL=1.8mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=15.5deg+-5deg
----------
----------
a=15.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-5deg b=34deg+-3deg
----------
----------
a=8deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)R = aa
(2)Rack position bb
(3)Drive side
----------
aa=37mm bb=2.5-0.5mm
----------
a=41.5deg+7deg-5deg b=(41.5deg)+-5deg
----------
aa=37mm bb=2.5-0.5mm
----------
a=41.5deg+7deg-5deg b=(41.5deg)+-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=5.6+-0.03mm
----------
a=(2deg)
----------
aa=5.6+-0.03mm
----------
a=(2deg)
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=5.3+-0.1mm
----------
----------
N1=325r/min Ra=5.3+-0.1mm
----------
0000002301 RACK SENSOR
(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=650r/min Ra=R1(11.2)mm
----------
----------
N1=650r/min Ra=R1(11.2)mm
----------
Have questions with 108621-2020?
Group cross 108621-2020 ZEXEL
108621-2020
INJECTION-PUMP ASSEMBLY