Information injection-pump assembly
ZEXEL
108822-2124
1088222124
Rating:
Service parts 108822-2124 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
ME161933
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/24.5{250}
14.
NOZZLE
Include in #1:
108822-2124
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108822-2124
1088222124
Zexel num
Bosch num
Firm num
Name
108822-2124
INJECTION-PUMP ASSEMBLY
14CK TICS HD-TI8M TICS
14CK TICS HD-TI8M TICS
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
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.
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
Adjusting point
-
Rack position
14.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148
146.4
149.6
Max. variation between cylinders
%
0
-3
3
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
9+-0.5
Pump speed
r/min
355
355
355
Average injection quantity
mm3/st.
20.5
18.5
22.5
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
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148
147
149
Basic
*
Fixing the lever
*
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+1.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
146
142
150
Fixing the lever
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
6.1+-0.0
5
0000001601
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:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Air cylinder ON
(4)Air cylinder OFF
(5)Damper spring setting
----------
T1=AC23
----------
----------
T1=AC23
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Air cylinder operating
(4)With air cylinder OFF
(5)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=(10)deg b=31deg+-3deg c=32deg+-5deg
----------
aa=37.5mm
----------
a=(10)deg b=31deg+-3deg c=32deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)At pump speed bb and rack position cc, set the stopper bolt. (Confirm non-injection.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31)deg
----------
aa=54mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31)deg
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=6deg bb=8.5+-0.03mm
----------
a=(45deg) b=(44deg)
----------
aa=6deg bb=8.5+-0.03mm
----------
a=(45deg) 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.
----------
----------
----------
----------
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+1.5mm
----------
----------
N1=1100r/min Ra=R1+1.5mm
----------
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=8.9+-0.1mm
----------
----------
N1=325r/min Ra=8.9+-0.1mm
----------
0000002401 AIR CYLINDER
<A> stopper bolt
<B> stopper bolt
<C> stopper bolt
(a) lever
(b) air cylinder
(c) speed lever
(d) Nut
(e) nut
(f) lever
(g) nut
1. Stopper bolt <A> adjustment method
(1)When air cylinder pressure is P1, set the gap between the lever (a) and the air cylinder (b) to L1.
(2)Confirm that the speed lever (c) operates between idling and full speed.
(3)Fix stopper bolt <A> using nut (d).
2. Stopper bolt <B> adjustment method.
(1)At air cylinder pressure P2, pump speed N1 and rack position is R1, adjust stopper bolt (B) so that the speed lever (c) is in the stop position.
(2)Turn the stopper bolt (c) so that the clearance between lever (a) and lever (f) is L2, then fix using nut (g).
(3)Move the lever (a) several times and fix stopper bolt <B> using the nut (e).
(4)Tightening torque T1 for nuts (d), (e) and (g)
----------
L1=1+0.5mm L2=0~1.5mm P1=0kPa(0kgf/cm2) P2=686+98kPa(7+1kgf/cm2) N1=530r/min R1=8.7+-0.1mm T1=4.9~6.86N-m(0.5~0.7kgf-m)
----------
----------
L1=1+0.5mm L2=0~1.5mm P1=0kPa(0kgf/cm2) P2=686+98kPa(7+1kgf/cm2) N1=530r/min R1=8.7+-0.1mm T1=4.9~6.86N-m(0.5~0.7kgf-m)
----------
Information:
If fuel line clamps are not installed in their exact location, vibration can cause the fuel lines to break and cause possible personal injury, or damage to the machine.
1. Disconnect front fuel injection lines (1), disconnect middle fuel injection lines (2) and rear fuel injection lines (3) from the fuel injection pump and the cylinder head assembly.2. Remove fuel injection lines (1), (2) and (3). Put caps or plugs on all fuel line connections to keep foreign material out of the fuel system.3. If a separation of the fuel lines has to be made, make sure the exact location of the clamps are marked for assembly purposes. Remove the clamps and make a separation of the fuel lines. The following steps are for the installation of the fuel injection lines.4. Remove the caps or plugs for the fuel injection line connections.5. If removed, connect the fuel lines with the clamps. Make sure the clamps are installed back in their correct location. Use Tool (A) to tighten the clamp bolts to a torque of 2.3 N m (20 lb in). For more information, see Specifications Manual SENR6470, of Testing & Adjusting Manual SENR6471.6. Install front fuel injection lines (1) on the fuel injection pump and cylinder head assembly.7 Install middle fuel injection lines (2) on the fuel injection pump and the cylinder head assembly.8. Install rear fuel injection lines (3) on the fuel injection pump and the cylinder head assembly.9. Tighten the fuel injection line nuts to a torque of 40 7 N m (30 5 lb ft).
Have questions with 108822-2124?
Group cross 108822-2124 ZEXEL
108822-2124
INJECTION-PUMP ASSEMBLY