108622-2210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086222210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108622-2210 1086222210

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Cross reference number

ZEXEL 108622-2210 1086222210

Zexel num

Bosch num

Firm num

Name

108622-2210

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. 31

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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 14.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 166 163 169

Max. variation between cylinders % 0 -2 2

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 8.4+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 14 12 16

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(14.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 166 164 168

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

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

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 155 151 159

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 250 250 250

Rack position R2-2

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 250 250 250

Rack position R2(R1-1. 8)

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

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

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 (4)Damper spring setting
----------
T1=AE37 BCL=2+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=17.5deg+-5deg b=33.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Normal engine position (Rack position corresponding to bb) (3)Set the stopper bolt so that speed = cc and rack position = dd (and confirm non-injection).
----------
aa=54mm bb=18mm cc=1100r/min dd=4+-0.3mm
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a=40deg+-5deg b=29.5deg+-5deg c=(30deg)

0000001301

(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=5deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)

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.
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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=1100r/min Ra=R1(14.7)+1mm
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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=8+-0.1mm
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Information:

COMPRESSION PRESSURE MEASUREMENT
1. Inspection Check to make sure -(1) The crankcase oil level is correct, and the air cleaner, starter and battery are all in normal condition.(2) The engine is at the normal operating temperature.2. Measurement (1) Move the control lever to a position for shutting off fuel supply.(2) Remove all glow plugs from the engine. Install the compression gauge and adapter (ST332270) combination to a cylinder on which the compression pressure is to be measured.
Compression gauge and adaptor
Measuring compression pressure(3) Turn the engine with the starter and read the gauge pressure at the instant the gauge pointer comes to stop.(4) If the gauge reading is below the limit, overhaul the engine.
a) Be sure to measure the compression pressure on all cylinders.b) The compression pressure varies with change of engine rpm. This makes it necessary to check engine rpm at the time of measuring the compression pressure.
a) It is important to measure the compression pressure at regular intervals to obtain the data on the gradual change of the compression pressure.b) The compression pressure would be slightly higher than the standard in a new or overhauled engine owing to break-in of the piston rings, valve seats, etc. It drops as the engine components wear down.
TROUBLESHOOTING
1. GeneralThe diagnosis of troubles, especially those caused by a faulty fuel injection pump or injection nozzles, or low compression pressure, can be difficult. It requires a careful inspection to determine not which item is the cause, but how many causes are contributing to the cause. Several causes may be contributing to a single trouble.On the following pages, there are troubleshooting charts on which engine troubles can be traced to their causes. Each chart has items to be verified ahead and suggested inspection procedure.Diesel engines exhibit some marked characteristics during operation. Knowing these characteristics will help minimize time lost in tracing engine troubles to their source. Following are the characteristics of diesel engines you should know about for diagnosis:* Combustion know (diesel knock)* Some black exhaust smoke (when the engine picks up load)* Vibration (due to high compression pressure and high torque)* Hunting (when the engine speed is quickly decreased)* Some white exhaust smoke (when the engine is cold, or shortly after the engine has been started) 2. Engine troubleshooting Problem 1: Hard starting(1) Items to be checked for ahead* Clogged air cleaner* Wrong oil grade for weather conditions * Poor quality fuel* Low cranking speed(2) Inspection procedure Problem 2: Fuel knockMore or less fuel knock occurs in diesel engines. This may be caused either by an excessively large delay period or by a too fast rate of fuel injection.(1) Items to be checked for ahead* Clogged air cleaner* Poor quality fuel(2) Inspection procedure Problem 3: Overheating(1) Items to be checked for aheadOverheating might also be caused by abnormal operating conditions. If the engine is overheating but its cooling system is not contributing to this trouble, it is necessary to check the difference between the ambient temperature and coolant temperature when the engine is in