108822-3160 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088223160


108822-3160 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108822-3160 1088223160

Cross reference number

ZEXEL 108822-3160 1088223160


Zexel num
Bosch num
Firm num
Name
108822-3160 
 
   
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
RED3 control unit part number   407910-3 960
RED3 rack sensor specifications mm   19
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   6.4 6.37 6.43
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
Rack position   (12.5)
Vist V   1.98 1.98 1.98
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   150.5 148.5 152.5
Max. variation between cylinders %   0 -2 2
Basic   *
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Injection quantity adjustment_02
Rack position   (6.7)
Vist V   2.9 2.8 3
Pump speed r/min   390 390 390
Average injection quantity mm3/st.   18.1 15.1 21.1
Max. variation between cylinders %   0 -15 15
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
 
0000001201
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:

Speed control lever angle

Test data 108822-3160
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg

0000000901

Test data 108822-3160
(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=6.4+-0.03mm
----------
a=(80deg)

0000001501

Test data 108822-3160
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.
----------

----------

0000001701

Test data 108822-3160
(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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