108621-2025 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086212025

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108621-2025 1086212025

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Service parts 108621-2025 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-0011

3. GOVERNOR 105487-5740

4. SUPPLY PUMP 105237-1840

5. AUTOM. ADVANCE MECHANIS 105681-8010

6. COUPLING PLATE 105664-0650

7. COUPLING PLATE

8. _ 159590-4522

9. _

10. NOZZLE AND HOLDER ASSY 105101-7421

11. Nozzle and Holder ME120897

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105030-4461

14. NOZZLE 105015-8221

15. NOZZLE SET

Include in #1:

108621-2025 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108621-2025 1086212025

Zexel num

Bosch num

Firm num

Name

108621-2025

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 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 *

_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 2.78 2.87

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:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator cancel stroke: BSL (5)Boost compensator stroke: BCL (6)Damper spring setting
----------
RT=1 TH=2mm 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=(41.5deg)+-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)

0000001901

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 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
----------

0000002301 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
----------

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
New DEF sensor kits are available. The new sensor kit allows the DEF sensor to be repaired on DEF manifold assemblies.Note: If troubleshooting procedures indicate a replacement of the DEF manifold, do not replace the DEF Manifold. Repair the DEF Manifold using the DEF manifold sensor kit.Refer to Table 1 for the appropriate DEF sensor kit for the DEF manifold installed.
Table 1
DEF manifold Part Number Part Description Repair with DEF Sensor Kit
462-3219 11 inch (279mm) Manifold 593-0641
462-3610 13 inch (330mm) Manifold 593-0642
462-3232 18 inch (457mm) Manifold 593-0643
Illustration 1 g06508474New disassembly and assembly instructions are available. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Disassemble and Disassembly and Assembly, Manifold (DEF Heater) - Assemble for the correct procedures.