Information injection-pump assembly
ZEXEL
108622-3520
1086223520
Rating:
Cross reference number
ZEXEL
108622-3520
1086223520
Zexel num
Bosch num
Firm num
Name
108622-3520
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1420
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
33
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Rack position
(13.8)
Vist
V
1.79
1.79
1.79
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
204
202
206
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(7.5)
Vist
V
2.7
2.6
2.8
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
15
12
18
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.4
2.35
2.45
Output voltage
V
2.95
2.94
2.96
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
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=3deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=3deg+-5deg b=37deg+-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
----------
a=(10deg)
----------
aa=6.4+-0.03mm
----------
a=(10deg)
0000001501
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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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 19 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:
1. Remove oil supply tube (1) and suction bell and tube (2). 2. Remove bolts (3) that hold the oil pump to the cylinder block and remove oil pump (4).3. To install, put oil pump (4) in position on the cylinder block. Install the bolts that hold the oil pump to the cylinder block.4. Put clean engine oil on the O-ring seals of the tubes.5. Install oil supply tube (1), suction bell and tube (2).End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump
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Group cross 108622-3520 ZEXEL
108622-3520
INJECTION-PUMP ASSEMBLY