108922-2040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1089222040


108922-2040 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108922-2040 1089222040

Cross reference number

ZEXEL 108922-2040 1089222040


Zexel num
Bosch num
Firm num
Name
108922-2040 
 
   
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   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
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   52
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
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
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-7
deg.   72 71.75 72.25
Difference between angles 3
Cal 1-8
deg.   117 116.75 117.25
Difference between angles 4
Cal 1-5
deg.   144 143.75 144.25
Difference between angles 5
Cal 1-6
deg.   189 188.75 189.25
Difference between angles 6
Cal 1-3
deg.   216 215.75 216.25
Difference between angles 7
Cal 1-4
deg.   261 260.75 261.25
Difference between angles 8
Cal 1-9
deg.   288 287.75 288.25
Difference between angles 9
Cal 1-10
deg.   333 332.75 333.25
Injection quantity adjustment
Adjusting point   -
Rack position   12.8
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   134 132.4 135.6
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8.5+-0.5
Pump speed r/min   330 330 330
Average injection quantity mm3/st.   19 17 21
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   8.4+-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(12.8)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   134 133 135
Basic   *
Fixing the lever   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.15
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   132 128 136
Fixing the lever   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Injection quantity adjustment_05
Adjusting point   C
Rack position   (R1-0.5)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   133 129 137
Fixing the lever   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
0000001601
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   *
Confirmation   *
_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 of operating range   *
_06
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05

Test data Ex:

Governor adjustment

Test data 108922-2040
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Air cylinder OFF (4)Air cylinder ON (5)Damper spring setting
----------
T1=AB86
----------

Speed control lever angle

Test data 108922-2040
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)When air cylinder OFF. (4)When air cylinder ON. (5)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=(17deg) b=27deg+-3deg c=30deg+-5deg

Stop lever angle

Test data 108922-2040
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Normal engine position (Rack position corresponding to dd)
----------
aa=31.5mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=42.5deg+-5deg b=13deg+-5deg c=(31deg)+-5deg

0000001301

Test data 108922-2040
(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
----------
aa=6deg bb=8.5+-0.03mm
----------
a=44deg30min+-3deg b=(44deg)

0000001901

Test data 108922-2040
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 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=8.5+-0.1mm
----------

0000002301 RACK SENSOR

Test data 108922-2040
(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=1050r/min Ra=R1(12.8)+1.15mm
----------

0000002401 AIR CYLINDER

Test data 108922-2040
(A) stopper bolt (B) stopper bolt (C) stopper bolt (a) lever (b) air cylinder (c) speed lever (d) Nut (e) nut 1. Stopper bolt A adjusting method (1)When air cylinder pressure is P1, set the gap between the lever (a) and the air cylinder (b) to L1. (2)Apply P2 to the air cylinder. (3)Confirm that the speed lever (c) operates between idling and full speed positions. (4)Fix the stopper bolt A using nut d. 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P1, pump speed N1 and rack position is Ra, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Move the lever a several times and then fix the stopper bolt B using the nut e. (3)Nut d tightening torque: T1 (4)Nut e tightening torque: T2
----------
L1=(1)mm P1=0kPa(0kgf/cm2) P2=392+98kPa(4+1kgf/cm2) N1=900r/min Ra=8.3+0.1mm T1=4.9~7N-m(0.5~0.7kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m)
----------




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