108821-2020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088212020

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108821-2020 1088212020

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Service parts 108821-2020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3770

3. GOVERNOR 105960-0070

4. SUPPLY PUMP 105237-0230

5. AUTOM. ADVANCE MECHANIS 105684-0130

6. COUPLING PLATE 105664-0990

7. COUPLING PLATE

8. _ 159640-0520

9. _

10. NOZZLE AND HOLDER ASSY 105110-7930

11. Nozzle and Holder ME095654

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

13. NOZZLE-HOLDER 105041-4300

14. NOZZLE

15. NOZZLE SET 105019-2420

Include in #1:

108821-2020 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108821-2020 1088212020

Zexel num

Bosch num

Firm num

Name

108821-2020

INJECTION-PUMP ASSEMBLY
8DC11

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 131424-8020

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

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

Digi switch no. 41

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 8.5 8.47 8.53

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (11.1)

PWM % 50.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 128 130

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_02

Rack position (6.8)

PWM % 26.5+-2. 8

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 23 20.4 25.6

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 950

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 1100

Advance angle deg. 2 1.5 2.5

Remarks
Finish

0000001201

Pre-stroke mm 8.5 8.47 8.53

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

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 4.5 4.45 4.55

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 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

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
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aa=20mm bb=1mm
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a=19deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=0deg bb=8.5+-0.03mm
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a=(50deg)

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

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
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Information:

Governor Linkage Adjustment
(1) Rod. (2) Nut. (3) Control lever. (4) Lever. (5) Pin. (6) High idle stop. (7) Locknut. (8) Low idle stop. (9) Locknut. (10) Decelerator treadle. (11) Floor plate. (12) Accelerator treadle. (13) Lever. (14) Rod. (15) Locknut. (16) Lever. (17) Locknut. (A) 9.7 mm (.38 in). (B) 4.8 mm (.19 in). (C) 38.1 mm (1.50 in). (D) 60.5 3.0 mm (2.38 .12 in). DO NOT USE control lever (3), or decelerator treadle (10) to shut OFF the engine.To shut engine OFF, pull up on accelerator treadle (12).1. Tighten nut (2) just enough so position of control lever (3) is not affected by the operation of the accelerator treadle (12) and decelerator treadle (10).2. With the parking brake ON and engine stopped, BE SURE disconnect switch is OFF.3. Remove pin (5).4. Loosen LOW IDLE stop (8) and HIGH IDLE stop (6) so they do not touch lever (13).5. Move control lever (3) to LOW IDLE position.6. Turn LOW IDLE stop (8) until it touches lever (13) and tighten locknut (9).7. Adjust length of rod (14) so distance from top of lever (16) to bottom of floor plate (11) is (C) 38.1 mm (1.50 in) as shown.8. Loosen locknut (15) and adjust length of rod so top of decelerator treadle (10) is (B) 4.8 mm (.19 in) above floor plate (11) as shown. If machine is equipped with a thick floor insulation pad, (used with enclosed cab), adjust decelerator treadle (10) so top of treadle is (A) 9.7 mm (.38 in) above top of floor plate and tighten locknut (15).9. Move control lever (3) to HIGH IDLE position.10. Turn HIGH IDLE stop (6) until it touches lever (13) and tighten locknut (7).11. Loosen locknut (17) and adjust accelerator treadle (12) so that distance from bottom of plate on treadle to top of floor plate (11) is (D) 60.5 3.0 mm (2.38 .12 in) as shown.12. Move lever (4) to HIGH IDLE position and adjust length of rod (1) so pin (5) can be installed.13. Install pin (5).
DO NOT adjust the linkage so the treadle can be used to shut off the engine. If the operator is in a standing position and places a foot on the treadle, the engine could be unexpectedly shut off, creating a situation where the machine can be difficult to control.
518 Skidder
1. Move governor shaft (3) to SHUT OFF position and install lever (2) on shaft (3) at angle (A).2. Adjust length of rod (5) so stop (4) on pedal (1) is at dimension (B) from the floor plate.Angle (A) ... 35 5°Dimension (B) ... 67 1 mm (2.64 .01 in)3. Tighten nut (6) ... 12 4 N m (9 3 lb ft)D5H
1. Move governor lever (2) to high idle and install spring (6). Move governor lever (2) to vertical position and adjust stop bolt (3) to contact lever (2), back off one turn and lock.2. Position lever (9) on the splined governor shaft