108922-2010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data


Information injection-pump assembly

ZEXEL 108922-2010 1089222010

Cross reference number

ZEXEL 108922-2010 1089222010


Zexel num Bosch num Firm num Firm Name
108922-2010        INJECTION-PUMP ASSEMBLY

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   8-3-600
Outer diameter - inner diameter - length (mm)
Overflow valve   131425-0220
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   407910-2 470
RED3 rack sensor specifications mm   15
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   52
Direction of rotation (viewed from drive side)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-2-7-8- 5-6-3-4- 9-10
Pre-stroke mm   8.5 8.47 8.53
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   45 44.75 45.25
Cyl.1-2
Difference between angles 2 deg.   72 71.75 72.25
Cal 1-7
Difference between angles 3 deg.   117 116.75 117.25
Cal 1-8
Difference between angles 4 deg.   144 143.75 144.25
Cal 1-5
Difference between angles 5 deg.   189 188.75 189.25
Cal 1-6
Difference between angles 6 deg.   216 215.75 216.25
Cal 1-3
Difference between angles 7 deg.   261 260.75 261.25
Cal 1-4
Difference between angles 8 deg.   288 287.75 288.25
Cal 1-9
Difference between angles 9 deg.   333 332.75 333.25
Cal 1-10


Injection quantity adjustment
Rack position   (11.2)
Vist V   1.75 1.75 1.75
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   134 133 135
Max. variation between cylinders %   0 -3 3
Basic   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5


Injection quantity adjustment_02
Rack position   (6.8)
Vist V   2.6 2.5 2.7
Pump speed r/min   330 330 330
Average injection quantity mm3/st.   19 17 21
Max. variation between cylinders %   0 -15 15
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-0.0 3
Remarks  
Refer to items regarding the pre-stroke actuator


0000001201
Pre-stroke mm   8.5 8.47 8.53
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   6.1 6.05 6.15
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   8.5 8.47 8.53
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   5.5
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:



Speed control lever angle

Test data 108922-2010 N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=16mm bb=1mm
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a=27deg+-5deg b=29deg+-5deg



0000000901

Test data 108922-2010 (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)B.T.D.C.: aa (7)Pre-stroke: bb
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aa=6deg bb=8.5+-0.03mm
----------
a=44deg30min+-3deg b=(44deg)



0000001501

Test data 108922-2010 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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0000001701

Test data 108922-2010 (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 15 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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0000001901 RACK SENSOR

Test data 108922-2010 (VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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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V1=1V
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Group cross 108922-2010 ZEXEL

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108922-2082  9 400 619 404  ME094787  INJECTION-PUMP ASSEMBLY
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