108622-3591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223591

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108622-3591 1086223591

Service parts 108622-3591 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3480

3. GOVERNOR 105923-2961

4. SUPPLY PUMP 105237-4690

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0740

7. COUPLING PLATE 156638-9920

8. _ 159600-6820

9. _

10. NOZZLE AND HOLDER ASSY 105101-8143

11. Nozzle and Holder 23600-2962B

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/23.5{240}

13. NOZZLE-HOLDER 105030-3670

14. NOZZLE

15. NOZZLE SET 105019-0940

Include in #1:

108622-3591 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108622-3591 1086223591

Zexel num

Bosch num

Firm num

Name

108622-3591

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 134424-4120

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 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. 33

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 -

Rack position 15.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 212 209 215

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.5+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 17 14 20

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(15.2)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 212 210 214

Basic *

Fixing the lever *

Boost pressure kPa 96 96

Boost pressure mmHg 720 720

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 171 165 177

Fixing the lever *

Boost pressure kPa 96 96

Boost pressure mmHg 720 720

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-3.85 )

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 118 115 121

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position (R2-3.85 )

Boost pressure kPa 8 8 10.7

Boost pressure mmHg 60 60 80

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 35)

Boost pressure kPa 82.6 82.6 82.6

Boost pressure mmHg 620 620 620

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

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 2.4 2.35 2.45

Output voltage V 2.95 2.94 2.96

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

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
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T1=AE81 BCL=(3.85)+-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 set position 'H'
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aa=42.5mm
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a=36deg+-3deg b=36deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At pump speed aa and rack position bb, set the stopper screw. (After setting, apply red paint.) (2)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever. (3)Use the hole above R = cc
----------
aa=0r/min bb=0.5+-0.3mm cc=30mm
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a=20deg+-5deg b=45deg+-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=6.4+-0.03mm
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a=(10deg)

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 Adjustment of the rack sensor (-2320) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (e) to the block (c). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)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.) (4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V). (5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
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L=43+-0.1mm N1=700r/min Ra=R1(15.2)mm
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