108622-3225 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223225

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108622-3225 1086223225

Cross reference number

ZEXEL 108622-3225 1086223225

Zexel num

Bosch num

Firm num

Name

108622-3225

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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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. 31

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 11

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 202 200 204

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Adjusting point B

Rack position R2(11.15 )

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 198 195 201

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 230 225 235

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

Rack limit *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point D

Rack position 4.1+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8.5 5.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_05

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R1(8.5)

Boost pressure kPa 10.7 10.7 12.7

Boost pressure mmHg 80 80 95

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position 11

Boost pressure kPa 70.6 70.6 70.6

Boost pressure mmHg 530 530 530

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

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). The pre-stroke at that time must be Pr1 (Pv1). (5)Stop lever setting: R2 (6)RACK LIMIT (7)Boost compensator stroke: BCL (8)Damper spring setting (9)Variable speed specification: idling adjustment (10)Main spring setting
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RT=1 TH=2.2mm N1=350r/min R1=4.1mm N2=1000r/min Q1=3mm3/st Pr1=4+-0.05mm Pv1=2.45+-0.01V R2=12.6+0.5mm BCL=(2.5)+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Stopper bolt setting
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aa=130mm
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a=1deg+-5deg b=(14.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=45mm
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a=25deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the rack position at bb before adjusting the governor (3)Set the stopper screw. (After setting, apply paint.)
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aa=35mm bb=12.6+0.5mm
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a=40deg+-5deg b=43deg+-5deg

0000001201

(1)Variable speed specification (2)Minimum - maximum speed specification (3)Use the hole at R = aa
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aa=112mm
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a=(17deg)+-5deg b=(19deg)

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(1deg)

0000001901

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.
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0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Mount the joint (B). (2)Select the shim (D) so that the rack limit's rack position is obtained at that time. (3)Install the rod (E) to the block (C). The distance between the pump end face and the rod (E) at rack limit must be L. 2. Rack sensor adjustment (-0020) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set at speed N. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (6)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)
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L=38-0.2mm N=1000r/min Ra=R2(11.15)mm
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0000002301 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
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L=1~2mm
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0000002401 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
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N1=500r/min N2=(750)r/min N3=(775)r/min N4=1000r/min RF=11mm Dr1=0.15mm Dr2=0+0.3mm
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