108822-3041 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088223041


108822-3041 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108822-3041 1088223041

Service parts 108822-3041 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108082-3190
3. GOVERNOR 105923-1431
4. SUPPLY PUMP 105237-4650
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2180
7. COUPLING PLATE
10. NOZZLE AND HOLDER ASSY 105101-7802
11. Nozzle and Holder 23600-2750A
12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}
13. NOZZLE-HOLDER 105030-3591
14. NOZZLE
15. NOZZLE SET 105019-0550

Include in #1:

108822-3041 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108822-3041 1088223041


Zexel num
Bosch num
Firm num
Name
108822-3041 
 
   
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.   41
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-8-6-2- 7-5-4-3
Pre-stroke mm   7.2 7.17 7.23
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-8
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-6
deg.   90 89.75 90.25
Difference between angles 3
Cyl.1-2
deg.   135 134.75 135.25
Difference between angles 4
Cal 1-7
deg.   180 179.75 180.25
Difference between angles 5
Cal 1-5
deg.   225 224.75 225.25
Difference between angles 6
Cal 1-4
deg.   270 269.75 270.25
Difference between angles 7
Cal 1-3
deg.   315 314.75 315.25
Injection quantity adjustment
Adjusting point   -
Rack position   13.9
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   148 145 151
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the rack   *
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4.8+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   7.9+-0.5
Pump speed r/min   375 375 375
Average injection quantity mm3/st.   14.3 11.3 17.3
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   7.1+-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(13.9)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   148 146 150
Basic   *
Fixing the lever   *
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4.8+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.95
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   136 130 142
Fixing the lever   *
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4.8+-0.0 5
0000001601
Pre-stroke mm   7.2 7.17 7.23
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   3.2 3.15 3.25
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   7.2 7.17 7.23
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

Test data 108822-3041
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point B (Ra) can be obtained at full setting.] (4)Stop lever's normal position setting: equivalent to RA (5)Damper spring setting
----------
T1=AD11 Ra=R1+0.95mm RA=(17)mm
----------

Speed control lever angle

Test data 108822-3041
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=88mm
----------
a=10deg+-5deg b=(35.5deg)+-3deg

Stop lever angle

Test data 108822-3041
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = aa (speed = bb) (2)Set the stopper bolt at rack position = cc (speed = dd). (3)At pin above R = ee
----------
aa=0.5+-0.3mm bb=0r/min cc=(17)mm dd=0r/min ee=35mm
----------
a=15deg+-5deg b=35deg+-5deg

0000001301

Test data 108822-3041
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove. (4)Damper (5)Pointer (6)Pre-stroke: aa (7)-
----------
aa=7.2+-0.03mm
----------
a=(80deg)

0000001901

Test data 108822-3041
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 108822-3041
(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=1100r/min Ra=R1(13.9)+0.95mm
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0000002301 AIR CYLINDER

Test data 108822-3041
(A): Speed lever (B): Adjusting bolt (C): Air cylinder (D): Locknut Adjustment of the air cylinder 1. Set the speed lever at the idling position. 2. Set the gap between the air cylinder (a) and the set bolt (b) to L1. 3. Set speed at N1 and apply positive pressure P1 to the air cylinder (c). Read the rack position value at the same speed. 4. Slowly push the set bolt (b) out and fix it using the nut (d) when the rack position is R1 at N1. 5. Apply positive pressure several times and confirm that the lever returns to the idle position at positive pressure P2. 6. Also, at positive pressure P1confirm that the rack position is R1 and complete adjustment.
----------
L1=(6)mm R1=7.5+-0.1mm N1=325r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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