108822-2280 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088222280

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108822-2280 1088222280

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Service parts 108822-2280 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3180

3. GOVERNOR 105923-1630

4. SUPPLY PUMP 105237-4810

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0990

7. COUPLING PLATE

8. _ 159600-3320

9. _ 156640-0420

10. NOZZLE AND HOLDER ASSY 105110-7381

11. Nozzle and Holder ME093732

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105041-4120

14. NOZZLE

15. NOZZLE SET 105019-0350

Include in #1:

108822-2280 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 108822-2280 1088222280

Zexel num

Bosch num

Firm num

Name

108822-2280

INJECTION-PUMP ASSEMBLY
14CK TICS HD-TI8M TICS

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 13.3

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 136.5 134.9 138.1

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 8.7+-0.5

Pump speed r/min 345 345 345

Average injection quantity mm3/st. 23.5 20.9 26.1

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(13.3)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 136.5 135.5 137.5

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+1.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 137 133 141

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.7)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 132.5 128.5 136.5

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=AC18
----------

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=37.5mm
----------
a=34deg+-5deg b=31.5deg+-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=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-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=4deg 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(13.3)+1.5mm
----------

Information:

Start By:a. remove exhaust manifoldsb. remove push rods and valve liftersc. remove water temperature regulators Put protection caps on all fuel openings. 1. Remove the bolts and valve cover base (1) from the cylinder head assembly.2. Disconnect hose (2) from the cylinder head assembly. 3. Put identification marks on wires (3), and disconnect them from the sending unit. 4. Remove six head bolts (4), and install Tooling (A). 5. Fasten a hoist to Tooling (A), and remove the remainder of the bolts that fasten the head assembly.6. Remove cylinder head assembly (5). The weight of the head assembly is 102 kg (224 lb). A new spacer plate gasket must be installed when the cylinder head is removed. See Remove & Install Spacer Plate.Install Cylinder Head Assemblies
1. Thoroughly clean the spacer plates and bottom surface of the cylinder head assemblies. Install a new head gasket and seals. Do not use any adhesives. A new spacer plate gasket must be installed when the cylinder head assembly is removed. See Remove And Install Spacer Plate. 2. Fasten Tooling (A) to the cylinder head assembly, and put cylinder head assembly (1) into position on the spacer plate. The use of guide bolts will help put the cylinder head assembly in alignment with the spacer plate.
(1) Large bolts (3/4 in). Put 6V-4876 Molycoat Paste Lubricant on the threads and between washer and underside of the cylinder head bolts. (2) Small bolts (3/8 in). See Step 3h.3. Install cylinder head bolts and washers. Tighten the bolts in the following sequence:a. Tighten bolts 1 through 10 in number sequence to 270 25 N m (200 20 lb ft)b. Tighten bolts 1 through 10 in number sequence to 470 20 N m (345 15 lb ft)c. Tighten bolts 1 through 10 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves.e. Tighten bolts 11 through 18 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 11 through 18 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 11 through 18 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the nine small bolts (2) to 45 7 N m (33 5 lb ft). 4. Connect hose (3) and the wire assembly to the cylinder head. 5. Install valve cover base (2) to the cylinder head. Tighten the bolts to a torque of 14 4 N m (10 3 lb ft) and the sequence as shown.End By:a. install water temperature regulatorsb. install push rods and valve liftersc. install exhaust manifolds