108822-2190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088222190

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108822-2190 1088222190

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Cross reference number

ZEXEL 108822-2190 1088222190

Zexel num

Bosch num

Firm num

Name

108822-2190

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 105780-2090

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

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)Damper spring setting
----------
T1=AC23
----------

Speed control lever angle

F:Full speed I:Idle (1)Viewed from feed pump side. (2)Use the hole at R = aa (3)Stopper bolt set position 'H'
----------
aa=30mm
----------
a=37deg+-5deg b=(31deg)+-3deg

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=45mm bb=1100r/min cc=4+-0.3mm dd=18mm
----------
a=(31deg)+-5deg b=25.5deg+-5deg c=41deg+-5deg

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.
----------

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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
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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
----------

Information:

Start By:a. remove oil pumpb. remove oil pan plate 1. Remove No. 1, 3, 5 and 7 main bearing caps (1). Remove the lower halves of the main bearings from the main bearing caps.
If the crankshaft is turned in the wrong direction, the tab on the bearing will be pushed between the crankshaft and the bearing area in the cylinder block. This can result in damage to the cylinder block and/or the crankshaft.
2. Install Tool (A) in the hole in the crankshaft journal, and turn the crankshaft to remove the upper halves of main bearings (2).3. Remove crankshaft thrust bearings (3) from the rear main bearing. Install the main bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and the main bearing caps.
4. Use Tool (A), and install new upper halves of main bearings (2) in the cylinder block. Install new lower halves of main bearings (2) in main bearing caps (1).
When the bearing clearance is checked and the engine is in an upright position (vertical position with cylinder head on top), the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances.
For complete details concerning measuring bearing clearances, see Engine Bearings And Crankshafts, Form No. SEBD0531.5. Check the main bearing clearance with Plastigage (B) as follows:a. Put a piece of Plastigage (B) on the crankshaft journals as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
b. Put main bearing caps (1) in position in the engine. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers. Install the bolts. Tighten the bolts to a torque of 40 4 N m (30 3 lb ft).c. Put a mark on each bolt and main bearing cap; then tighten the bolts 90° more.d. Remove the main bearing caps, and measure the Plastigage to find the bearing clearance. The main bearing clearance for new bearings must be 0.076 to 0.165 mm (.0030 to .0065 in.). Maximum permissible clearance with used bearings is 0.25 mm (.010 in.). 6. Put clean oil on the thrust bearing, and install a new thrust bearing for the rear main bearing. Install the thrust bearing with the identification "BLOCK SIDE" toward the cylinder block and the tabs on the thrust bearings