108621-2024 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086212024


108621-2024 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108621-2024 1086212024

Service parts 108621-2024 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-0011
3. GOVERNOR 105487-5740
4. SUPPLY PUMP 105237-1840
5. AUTOM. ADVANCE MECHANIS 105681-8010
6. COUPLING PLATE 105664-0650
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105101-7421
11. Nozzle and Holder ME120897
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}
13. NOZZLE-HOLDER 105030-4461
14. NOZZLE 105015-8221
15. NOZZLE SET

Include in #1:

108621-2024 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108621-2024 1086212024


Zexel num
Bosch num
Firm num
Name
108621-2024 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
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
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
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   11.1
Pump speed r/min   650 650 650
Each cylinder's injection qty mm3/st.   167.5 163.3 171.7
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
 
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(11.1)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   167.5 166.5 168.5
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   R1-1.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   137.5 131.5 143.5
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.   165 145 185
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(11.1)
Boost pressure kPa   20 20 20
Boost pressure mmHg   150 150 150
Timer adjustment
Pump speed r/min   640--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   590
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   840
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 
0000001601
Pre-stroke mm   5.6 5.57 5.63
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   5 4.5 5.5
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   5.6 5.57 5.63
Output voltage V   1 1 1.05
Adjustment   *
Remarks
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 2.78 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

Test data 108621-2024
N:Pump speed R:Rack position (mm) (1)Boost compensator cancel stroke: BSL (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
BSL=1.8mm BCL=1.6+-0.1mm
----------

Speed control lever angle

Test data 108621-2024
F:Full speed
----------

----------
a=16deg+-5deg

0000000901

Test data 108621-2024
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=8deg+-5deg b=33.5deg+-3deg

Stop lever angle

Test data 108621-2024
N:Pump normal S:Stop the pump. (1)Use the hole at 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

0000001301

Test data 108621-2024
(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)

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
----------

0000002301 RACK SENSOR

Test data 108621-2024
(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(11.1)mm
----------




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Group cross 108621-2024 ZEXEL

 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY
108621-2024  
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Mitsubishi 

9 400 619 095 
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