108622-3227 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223227


108622-3227 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108622-3227 1086223227

Cross reference number

ZEXEL 108622-3227 1086223227


Zexel num
Bosch num
Firm num
Name
108622-3227 
 
   
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   105780-8250
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   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   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.   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.   191.5 189.5 193.5
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   11.15
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   199 193 205
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   (12.3)+- 0.1
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   250 245 255
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   -
Rack position   4.7+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   14 11 17
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   E
Rack position   R1(8.6)
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   132.5 129.5 135.5
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
Injection quantity adjustment_06
Adjusting point   F
Rack position   9.2+-0.5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 120
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(8.6)
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

Test data 108622-3227
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
----------
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=(2.4)+-0.1mm
----------

Speed control lever angle

Test data 108622-3227
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Stopper bolt setting
----------
aa=130mm
----------
a=1deg+-5deg b=(14.5deg)+-5deg

0000000901

Test data 108622-3227
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 108622-3227
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.)
----------
aa=35mm bb=12.6+0.5mm
----------
a=40deg+-5deg b=43deg+-5deg

0000001201

Test data 108622-3227
(1)Variable speed specification (2)Minimum - maximum speed specification (3)Use the hole at R = aa
----------
aa=112mm
----------
a=(17deg)+-5deg b=(19deg)

0000001301

Test data 108622-3227
(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=(1deg)

0000001901

Test data 108622-3227
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 RACK SENSOR

Test data 108622-3227
(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)
----------
L=38-0.2mm N=1000r/min Ra=11.15mm
----------

0000002301 LEVER

Test data 108622-3227
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.
----------
L=1~2mm
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0000002401 GOVERNOR TORQUE CONTROL

Test data 108622-3227
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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Group cross 108622-3227 ZEXEL

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