108822-2700 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088222700

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108822-2700 1088222700

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Cross reference number

ZEXEL 108822-2700 1088222700

Zexel num

Bosch num

Firm num

Name

108822-2700

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 13.3

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.
----------

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0000002201 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=335r/min Ra=8.3+-0.1mm
----------

0000002301 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:

These fuel heater groups raise the temperature of the diesel fuel before it goes to the engine so it will flow freely in cold temperatures. Engine jacket water is used to heat the fuel in the heater. These groups are installed in similar procedures for all machines. See the instruction that follows for the correct installation procedures. Use pipe thread sealant on all pipe thread connections.3T1356 Heater Group (D8L)
(1) Drain the coolant from the radiator, and drain the fuel from the fuel tank. Disconnect heater hoses (1) and (2) from the heater. Install 8T2270 Tees (3), (4) and (5), as shown, where hoses (1) and (2) were removed. Connect hoses (1) and (2) to tees (3) and (5). Install 6J7366 cap (6) on tee (4). (2) Remove fuel filter (7) and stud (8). Put 9S3263 Thread Lock on 8N2101 Stud (9) and install stud (9) where stud (8) was removed. Install 8N9730 Fuel Heater (10) and an 8N2301 Seal on stud (9) with 8N2100 Connector (11). Put thread lock on connector (11). Tighten connector (11) 3/4 turn (270°) after it makes contact with heater (10). Install fuel filter (7) on connector (11). Connect 4V3410 Hose Assemblies (12) and (13) to tees (3) and (5); use thread lock on the threads. Connect hoses (12) and (13) to fuel heater (10) as shown, with two 5D1026 Clamps.3T6833 Fuel Heater (D8L)
(1) Drain the coolant from the radiator, and drain the fuel from the fuel tank. Remove cover (1) and plug (2); these parts will not be needed again. Install 6T6 Cover (3) and a 4N790 Gasket where cover (1) was removed; use the former hardware. Install 5P7747 Valve Assembly (4) and 307964 Elbow (5) in cover (3). Install 6B4661 Bushing (6), 9N3666 Valve Assembly (7) and 17004 Connector (8) where plug (2) was removed. (2) Connect 3T7673 Hose Assembly (9) to valve (7); connect 3T9872 Hose Assembly (10) to elbow (5). Put hoses (9) and (10) in position under the radiator and along the frame left rail. Fasten hoses (9) and (10) to existing bosses, bolts or brackets with 5D0718 Clips (11), S509 Bolts and 5M2894 Washers. Fasten hose (10) to the radiator guard with 9M4972 Clip (12), an S509 Bolt and 5M2894 Washer. (3) Remove fuel filter (13) and stud (14). Install 8N2101 Stud (15) with 9S3263 Thread Lock where stud (14) was removed. Install 8N9730 Fuel Heater (16) and a 8N2301 Seal on stud (15) with 8N2100 Connector (17); turn the connector 3/4 turn (270°) after it makes contact with the fuel heater. Install fuel filter (13). Connect hoses (9) and (10) to fuel heater (16) with two 5D1026 Clamps.6T1863 Heater Group (D9L)
(1) Install two 62325 Elbows (1) and (2) in 8N9593 Heater (3). Fasten heater (3) to an existing boss on the frame with a 6V2855 Grommet, 6V2853 and 6V2854 Clips, two S1591 Bolts and 5P1075 Washers. Disconnect heater