Information injection-pump assembly
ZEXEL
108822-2060
1088222060

Rating:
Service parts 108822-2060 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/24.5(250)
15.
NOZZLE SET
Include in #1:
108822-2060
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108822-2060
1088222060
Zexel num
Bosch num
Firm num
Name
108822-2060
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
105780-8230
Nozzle
105780-0110
Bosch type code
DN0SN059
Nozzle holder
105780-2170
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
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.
42
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25
Cyl.1-2 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25
Cal 1-8 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(11.3)
Vist
V
1.73
1.73
1.73
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
119.5
118.5
120.5
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
Injection quantity adjustment_02
Rack position
(7.5)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
23
21
25
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
Refer to items regarding the pre-stroke actuator
0000001201
Pre-stroke
mm
8.5
8.47
8.53
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
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
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:
Speed control lever angle

N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=16mm bb=1mm
----------
a=26deg+-5deg b=29deg+-5deg
----------
aa=16mm bb=1mm
----------
a=26deg+-5deg b=29deg+-5deg
0000000901

(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=6deg bb=8.5+-0.03mm
----------
a=45deg16min+-3deg b=(44deg)
----------
aa=6deg bb=8.5+-0.03mm
----------
a=45deg16min+-3deg b=(44deg)
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.
----------
----------
----------
----------
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.
----------
----------
----------
----------
0000001901 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 (154610-0620)
(1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01.
(2)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)
----------
V1=1V
----------
----------
V1=1V
----------
Information:
3176 Electronic Governor Fuel Injection
The ECM controls the amount of fuel injected, by varying signals to the injectors. The injectors will inject fuel ONLY if the injector solenoid is energized. The ECM sends a 100 volt signal to the solenoid to energize it. By controlling the timing and duration of the 100 volt signal, the ECM can control injection timing and the amount of fuel injected.The ECM sets certain limits on the amount of fuel that can be injected. "FRC Fuel Pos" is a limit based on boost pressure to control the fuel-air ratio, for emissions control purposes. When the ECM senses a higher boost pressure (more air into cylinder), it increases the "FRC Fuel Pos" limit (allows more fuel into cylinder). "Rated Fuel Pos" is a limit based on the horsepower rating of the engine. It is similar to the rack stops and torque spring on a mechanically-governed engine. It provides horsepower and torque curves for a specific engine family and rating. All of these limits are programmed by the factory into the Personality Module and are not programmable in the field.Injection timing depends on engine rpm, load and other operation factors. The ECM knows where top-dead-center of cylinder number one is from the signal provided by the engine Speed/Timing Sensor. It decides when injection should occur relative to top-dead-center and provides the signal to the injector at the desired time.Under certain conditions, the 3176 Engine may intentionally operate on just three cylinders. This feature is called "Three Cylinder Cutout" and occurs when the engine is operated under no load, at high rpm (when signals to the injectors are of very short duration). Under these conditions, the ECM does not inject fuel into cylinders 4, 5 and 6. This allows for more precise fuel metering to cylinders 1, 2 and 3. The accompanying change in feel and sound of the engine should not be misdiagnosed as an engine problem. When more power is needed, all six cylinders will be fueled and full power delivered.Programmable Parameters
Certain parameters that affect 3176 Vehicular Diesel Engine operation may be changed through electronic service tools (either the ECAP or DDT). The parameters are stored in the ECM and passwords are used to prevent unauthorized changes.Password protected parameters are either "System Configuration Parameters" or "Customer Specified Parameters". System Configuration Parameters are set at the factory and affect emissions or horsepower ratings within a family of engines. Factory passwords must be obtained and used to change System Configuration Parameters. Customer Specified Parameters are variable and can be used to affect such things as the rpm/horsepower ratings within the limits set by the factory. Customer Passwords must be used to change Customer Specified Parameters.If the operator has not had adequate training, some parameters may affect engine operation in ways that are not expected. This may lead to power or performance complaints, even though the engine is operating correctly.Passwords
"System Configuration Parameters" are protected by factory passwords. System Configuration Parameters are those that affect horsepower family or
The ECM controls the amount of fuel injected, by varying signals to the injectors. The injectors will inject fuel ONLY if the injector solenoid is energized. The ECM sends a 100 volt signal to the solenoid to energize it. By controlling the timing and duration of the 100 volt signal, the ECM can control injection timing and the amount of fuel injected.The ECM sets certain limits on the amount of fuel that can be injected. "FRC Fuel Pos" is a limit based on boost pressure to control the fuel-air ratio, for emissions control purposes. When the ECM senses a higher boost pressure (more air into cylinder), it increases the "FRC Fuel Pos" limit (allows more fuel into cylinder). "Rated Fuel Pos" is a limit based on the horsepower rating of the engine. It is similar to the rack stops and torque spring on a mechanically-governed engine. It provides horsepower and torque curves for a specific engine family and rating. All of these limits are programmed by the factory into the Personality Module and are not programmable in the field.Injection timing depends on engine rpm, load and other operation factors. The ECM knows where top-dead-center of cylinder number one is from the signal provided by the engine Speed/Timing Sensor. It decides when injection should occur relative to top-dead-center and provides the signal to the injector at the desired time.Under certain conditions, the 3176 Engine may intentionally operate on just three cylinders. This feature is called "Three Cylinder Cutout" and occurs when the engine is operated under no load, at high rpm (when signals to the injectors are of very short duration). Under these conditions, the ECM does not inject fuel into cylinders 4, 5 and 6. This allows for more precise fuel metering to cylinders 1, 2 and 3. The accompanying change in feel and sound of the engine should not be misdiagnosed as an engine problem. When more power is needed, all six cylinders will be fueled and full power delivered.Programmable Parameters
Certain parameters that affect 3176 Vehicular Diesel Engine operation may be changed through electronic service tools (either the ECAP or DDT). The parameters are stored in the ECM and passwords are used to prevent unauthorized changes.Password protected parameters are either "System Configuration Parameters" or "Customer Specified Parameters". System Configuration Parameters are set at the factory and affect emissions or horsepower ratings within a family of engines. Factory passwords must be obtained and used to change System Configuration Parameters. Customer Specified Parameters are variable and can be used to affect such things as the rpm/horsepower ratings within the limits set by the factory. Customer Passwords must be used to change Customer Specified Parameters.If the operator has not had adequate training, some parameters may affect engine operation in ways that are not expected. This may lead to power or performance complaints, even though the engine is operating correctly.Passwords
"System Configuration Parameters" are protected by factory passwords. System Configuration Parameters are those that affect horsepower family or
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Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
108822-2060
INJECTION-PUMP ASSEMBLY