108621-2006 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086212006

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108621-2006 1086212006

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 108621-2006 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 108621-2006 1086212006

Zexel num

Bosch num

Firm num

Name

108621-2006

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 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-7220

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 21

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 5.6 5.57 5.63

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 11.1

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 167.5 163.3 171.7

Basic *

Fixing the rack *

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_02

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 11.6 9.9 13.3

Fixing the rack *

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 167.5 166.5 168.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1-1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 139 133 145

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 165 145 185

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V V1+0.13+ -0.01

PS407980-224* mm 5.4+-0.0 3

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R2(R1-1. 6)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(11.1)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 640--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 590

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 840

Advance angle deg. 2 1.5 2.5

Remarks
Finish

0000001601

Pre-stroke mm 5.6 5.57 5.63

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 5 4.5 5.5

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 5.6 5.57 5.63

Output voltage V 1 1 1.05

Adjustment *

Remarks
Output voltage V1

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.6 2.32 2.88

Output voltage V 2.8 2.73 2.87

Confirmation *

_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

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator cancel stroke: BSL (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
BSL=1.8mm BCL=1.6+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=16deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=8deg+-5deg b=33.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb (3)Drive side
----------
aa=37mm bb=2.5-0.5mm
----------
a=41.5deg+7deg-5deg b=(59deg)+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.6+-0.03mm
----------
a=(2deg)

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=5.3+-0.1mm
----------

0000002301 RACK SENSOR

(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=650r/min Ra=R1(11.1)mm
----------

Information:

Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Required Parts
Table 2
Required Parts
Item Qty Part Number Part Name
1 1 574-7991 Film Field Rework Procedure
Illustration 1 g06471195
DEF injector hose connector contacting the clearance hole
Visually inspect the DEF injector clearance hole for evidence of rub and wear for the DEF injector hose connector.
Illustration 2 g06480781
Clearance hole before grinding
Illustration 3 g06471198
Detail of area A
(D1) 12.1 mm (0.48 inch)
(D2) 75 mm (2.9 inch)
(D3) 50 mm (1.96 inch)
Illustration 4 g06471200
(D4) 50 mm (1.96 inch)
(D5) 12.6 mm (0.49 inch)
(D6) 11.7 mm (0.46 inch)
(D7) 75 mm (2.9 inch)
(D8) Radius is 35 mm (1.4 inch)
If evidence of contact is found, remove the hose connector from the DEF injector. Use die-grinder to increase size of the clearance hole from outside of the machine. Refer to the dimensions that are provided in Illustration 3 and Illustration 4.Note: To prevent unexpected lowering of the lift arms, use a lift arm safety brace to lock the lift arms in raised position. Refer to Operation and Maintenance Manual , SEBU9084 , "Loader Lift Arm Brace Operation".
Illustration 5 g06471201
DEF hose reconnected to outer connector
After the clearance hole is increased, connect the hose connector for DEF to the outer connector on the DEF injector. Verify the clearance between the frame and the DEF hose connector.
Illustration 6 g06471202
Increased clearance hole
Rotate hose connector towards front of machine. Refer to Illustration 6 for proper orientation. The increased hole is large enough to provide clearance for the hose connector.
Illustration 7 g06471206
(1) 574-7991 Film
Paint any bare metal to prevent rust and cover the clearance hole with film (1).