108622-1091 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086221091 1156032711


108622-1091 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108622-1091 1086221091
ISUZU 1156032711 1156032711

Service parts 108622-1091 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-3610
3. GOVERNOR 105923-3950
4. SUPPLY PUMP 105237-4740
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-2261
7. COUPLING PLATE
10. NOZZLE AND HOLDER ASSY 105110-7581
11. Nozzle and Holder 1-15300-359-0
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.1{225}
13. NOZZLE-HOLDER 105041-4161
14. NOZZLE
15. NOZZLE SET 105019-0790

Include in #1:

108622-1091 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108622-1091 1086221091
ISUZU 1156032711 1156032711


Zexel num
Bosch num
Firm num
Name
108622-1091 
108622-1092 
 
1156032711  ISUZU
INJECTION-PUMP ASSEMBLY
6SD1-TC * K 14CJ TICS HD-TI6M TICS

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   131424-7120
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.   32
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   8.5 8.47 8.53
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.75 60.25
Difference between angles 2
Cal 1-3
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cyl.1-2
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-4
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   -
Rack position   12.2
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   146.5 144.5 148.5
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   6.7+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   14.5 11.3 17.7
Max. variation between cylinders %   0 -13 13
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(12.2)
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   146.5 144.5 148.5
Basic   *
Fixing the lever   *
Boost pressure kPa   48 48
Boost pressure mmHg   360 360
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   6.1+-0.0 5
Boost compensator adjustment
Pump speed r/min   530 530 530
Rack position   R2-1.8
Boost pressure kPa   4 4 6.7
Boost pressure mmHg   30 30 50
Boost compensator adjustment_02
Pump speed r/min   530 530 530
Rack position   R2(R1-1. 25)
Boost pressure kPa   34.7 34.7 34.7
Boost pressure mmHg   260 260 260
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   *
_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:

Governor adjustment

Test data 108622-1091
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
----------
T1=AE40 BCL=1.8+-0.1mm
----------

Speed control lever angle

Test data 108622-1091
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=22.5deg+-5deg b=28.5deg+-3deg

Stop lever angle

Test data 108622-1091
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt. (Confirm non-injection.)
----------
aa=40mm
----------
a=14deg+-5deg b=41deg+-5deg

0000001301

Test data 108622-1091
(1)Pump vertical direction (2)Position of damper's threaded hole 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=5deg bb=8.5+-0.03mm
----------
a=(50deg) b=(44deg)

0000001901

Test data 108622-1091
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 TAMPER PROOF

Test data 108622-1091
SW:Inner hexagonal SW14 (F): Apply thread lock adhesive . (G): Full tamper proof (H): Full boost (Full rack) (I): 0 boost 1. Mount (C) and (D) after adjusting the boost compensator. 2. Back off the load lever set screw L1 from the end face of the governor housing.. 3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C. 4. Fix using the nut (D). 5. Next, after adjusting the stop lever, confirm the point aa. 6. Reset the load lever to the full boost rack. 7. After completion of setting, seal using the plug (E).
----------
L1=6+1mm N1=1100r/min Ra=R1(12.2)+1.3mm Q1=(154.5)mm3/1000st aa=E
----------
T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)

0000002301 TAMPER PROOF

Test data 108622-1091
(A): Rotation tamper proof (B): Full-speed setting 1. Back off the full-speed set bolt. 2. Confirm that the tamper setting position is N1, R1, Q1. 3. At that time, record the angle of the speed lever. 4. After confirming the above setting, set full speed.
----------
N1=1360r/min R1=(6.9)mm Q1=-
----------

0000002401 RACK SENSOR

Test data 108622-1091
G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.2)+0.8mm N1=1100r/min V1=3+-0.01V
----------




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Group cross 108622-1091 ZEXEL

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