108822-2141 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088222141

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108822-2141 1088222141

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 108822-2141 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 108822-2141 1088222141

Zexel num

Bosch num

Firm num

Name

108822-2141

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. 42

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

Adjusting point -

Rack position 13.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 150.5 148.9 152.1

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 320 320 320

Average injection quantity mm3/st. 23 21 25

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(13.9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 150.5 149.5 151.5

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+1.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 154 150 158

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

_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)Air cylinder OFF (4)Air cylinder ON (5)Damper spring setting
----------
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)When air cylinder OFF. (4)When air cylinder ON. (5)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=(8deg) b=(31deg)+-3deg c=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Normal engine position (Rack position corresponding to dd)
----------
aa=31.5mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=41deg+-5deg b=13deg+-5deg c=(31deg)

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=45deg16min+-3deg 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(13.9)+1.7mm
----------

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=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 1. Stopper bolt A adjusting method (1)When air cylinder pressure is P1, set the gap between the lever (a) and the air cylinder (b) to L1. (2)Apply P2 to the air cylinder. (3)Confirm that the speed lever (c) operates between idling and full speed positions. (4)Fix the stopper bolt A using nut d. 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P1, pump speed N1 and rack position is Ra, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Move the lever a several times and then fix the stopper bolt B using the nut e. (3)Nut d tightening torque: T1 (4)Nut e tightening torque: T2
----------
L1=(1)mm P1=0kPa(0kgf/cm2) P2=392+98kPa(4+1kgf/cm2) N1=350r/min Ra=9+-0.1mm T1=4.9~7N-m(0.5~0.7kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m)
----------

Information:

2. Turn the crankshaft until two pistons are at bottom center.3. Remove bolts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons & Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use Tool (A), and install piston (2) and the connecting rod in the cylinder liner.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the nuts, and tighten them to a torque of 90 8 N m (67 6 lb ft). Put a mark on the nuts and cap, and tighten the nuts an extra 90 5 degrees.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install piston cooling tubesb. install oil pumpc. install cylinder head assemblyDisassemble & Assemble Pistons & Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with Tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with Tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Bearing Removal And Installation Tools, Special Instructions, SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260°C (350° to 500° F). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of Tool (C). Put a new rod pin bearing (6) on the adapter part of Tool (C). The old bearing is pushed out by Tool (C) as the new bearing is installed.7. Use Tool (C) to push the new bearing into the connecting rod until the push adapter of Tool (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in).9. Check the clearance between the ends of the piston rings. See the topic, "Pistons & Rings" in Specifications Manual, SENR6470.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint.11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston. Use Tool (B) to install