108622-0030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086220030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108622-0030 1086220030

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Cross reference number

ZEXEL 108622-0030 1086220030

Zexel num

Bosch num

Firm num

Name

108622-0030

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 132424-0620

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

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. 21

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Rack position (12.9)

Vist V 1.41 1.41 1.41

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 177.6 175.6 179.6

Max. variation between cylinders % 0 -4 4

Basic *

PS407980-224* V V1+0.59+ -0.01

PS407980-224* mm 5.4+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_02

Rack position (7.7)

Vist V 2.5 2.4 2.6

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -10 10

PS407980-224* V V1+0.59+ -0.01

PS407980-224* mm 5.4+-0.0 3

0000001201

Pre-stroke mm 6.4 6.37 6.43

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 4 3.95 4.05

Output voltage V 2.62 2.61 2.63

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

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 3.4

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

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=16mm bb=1mm
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a=12deg+-5deg b=29deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=6.4+-0.03mm
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a=(30deg)

0000001501

(A): Pre-stroke actuator (B): Stamp housings A and B at the same time. (C): Stamping range 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (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 counterclockwise 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

(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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Information:

Illustration 48 g06190445
520-9215 Junction Box As
Install the terminal strip rail in the new junction box.
Install the button plugs and harness nuts in the new junction box.
Illustration 49 g06190413
Replace terminal blocks 1, 2, 10, and 11 with new 314-9086 Terminal Block and 314-9090 Terminal Cover.
Illustration 50 g06190439
(1) 419-4954 Gaskets
Route harnesses through the two exterior gaskets (1) and the nuts (interior) and land in terminal blocks.
Illustration 51 g06190441
Install the terminal markers on new terminals 1, 2, 10, and 11.
Illustration 52 g06190442
(2) 438-9639 Film
(3) 133-6623 Wire As
Attach ground wire (3) to the junction box and the door of the junction box.
Attach film (2) to the junction box door.
Check the continuity from terminal blocks to connector.Converting a 438-0996 Box Wiring Gp/ 438-0992 Box Wiring Gp to a 521-2975 Box Wiring Gp/ 521-2976 Box Wiring Gp
Removal Procedure
Illustration 53 g06184633
Illustration 54 g06184635
Illustration 55 g06184638
Disassemble the box wiring group.
Remove the terminal strip rail.
Remove the wires from terminal blocks.Installation Procedure
Table 18
New Parts
Qty Part Number Part Name
1 133-6623 Wire As
1 419-4954 Gasket
1 450-9656(1) Film
1 450-9658(2) Film
1 520-9217 Junction Box As
(1) The 450-9656 Film is for the 521-2976 Box Wiring Gp outlet of the CEM.
(2) The 450-9658 Film is for the 521-2975 Box Wiring Gp inlet of the CEM.
Illustration 56 g06190450
(1) 520-9217 Junction Box As
Install the terminal strip rail in the new junction box.
Install the button plug and harness nut in the new junction box.
Illustration 57 g06190453
(1) Cover plate
(2) 419-4954 Gasket
Route harness through the one exterior gasket (2) and the nut (interior) and land in terminal blocks.
Relocate the cover plate (1) from the top to the bottom.
Illustration 58 g06190462
(3) 133-6623 Wire As
(4) 438-9639 Film
Attach ground wire (3) to the junction box and the door of the junction box.
Attach film (4) to the junction box door.
Check the continuity from terminal blocks to connector.