Information injection-pump assembly
ZEXEL
108622-3170
1086223170
HINO
220008210A
220008210a
Rating:
Service parts 108622-3170 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2412E
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/23.5{240}
14.
NOZZLE
Include in #1:
108622-3170
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3170
1086223170
HINO
220008210A
220008210a
Zexel num
Bosch num
Firm num
Name
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1420
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
31
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.9
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
204
202
206
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
194
188
200
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
230
225
235
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
Rack limit
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_04
Adjusting point
D
Rack position
4.1+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
9
6
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_05
Adjusting point
F
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
7.9
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
10.9
Boost pressure
kPa
37.3
37.3
37.3
Boost pressure
mmHg
280
280
280
0000001601
Pre-stroke
mm
6.4
6.37
6.43
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
4
3.95
4.05
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
6.4
6.37
6.43
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
3.4
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)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05
(4)Deliver without the torque control spring operating.
(5)Stop lever setting: R1
(6)RACK LIMIT
(7)Boost compensator stroke: BCL
(8)Damper spring setting
----------
RT=1 TH=2mm R1=12.6+0.5mm BCL=3+-0.1mm
----------
----------
RT=1 TH=2mm R1=12.6+0.5mm BCL=3+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=11deg+-5deg
----------
----------
a=11deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=37.5deg+-3deg
----------
aa=45mm
----------
a=25deg+-5deg b=37.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set stopper screw so that rack position = bb (after setting apply red paint).
(3)Set before governor adjustment.
----------
aa=35mm bb=12.6+0.5mm
----------
a=40deg+-5deg b=43deg+-5deg
----------
aa=35mm bb=12.6+0.5mm
----------
a=40deg+-5deg b=43deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(1deg)
----------
aa=6.4+-0.03mm
----------
a=(1deg)
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 limit adjustment
(1)Mount the joint (B).
(2)Select the shim (D) so that the rack limit's rack position is obtained at that time.
(3)Install the rod (E) to the block (C).
The distance between the pump end face and the rod (E) at rack limit must be L.
2. Rack sensor adjustment (-0020)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set at speed N.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(6)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)
----------
L=38-0.2mm N=1000r/min Ra=(10.9)mm
----------
----------
L=38-0.2mm N=1000r/min Ra=(10.9)mm
----------
Information:
Fuel System Bleeding
Fuel system bleeding(1) Loosen the air vent plug on the fuel filter. (approx. 1.5 turns)(2) Move the priming button for the filter up and down.(3) When fuel flowing from the vent hole no longer contains air bubbles, tighten the vent plug.Inspection and Adjustment of No-Load Minimum (Low Idling) Speed and Maximum Speed
(a) The following adjustments were inspected and set for each engine on the test bench at the factory, and the set bolts are sealed. These settings should be checked and adjusted only at our designated service shop.(b) After the governor parts are adjusted, all external stoppers must be sealed in the same way as when adjustments were made at the factory.(c) Whether the seals are intact or not has important bearing on the validity of claims under warranty. Be sure to seal all the specified sections.(d) When inspecting or adjusting, be ready to operate the engine stop lever manually in case the engine overruns (engine operation at extremely high speed).
Prior to inspection and adjustment, conduct a warm-up operation until the coolant and oil temperatures rise above 70 °C [158 °F].(1) Starting the engine
Inspection and adjustment of no-load minimum (low idling) speed and maximum speed(a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch.(b) The engine ignites when the rotation speed reaches approximately 150 min-1, and the engine speed rises. Operate the speed control lever to maintain the engine speed between 800 and 1000 min-1.(c) After the engine speed stabilizes, return the speed control lever to the low idling position.(2) Low idling setting (no-load minimum rotation speed setting)Hold the speed control lever at the position of no-load minimum rotation speed, then secure the lever in that position using the idling adjustment screw.
If there is speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range.
(3) Governor setting (maximum rotation speed setting)(a) Keep the speed control lever at the position of the specified maximum rotation speed.(b) With the speed control lever held in that position, adjust and set the governor set bolt (maximum rotation speed set screw) to the specified rotation speed).Inspection of V-Belt Tension
(1) Press the V-belt at a midpoint between the alternator and crankshaft pulley to check the mount of belt deflection.
Inspection of V-belt tension (2) If the amount of belt deflection does not conform to the standard value, loosen the adjusting bolt and move the alternator to adjust the belt tension.Engine Break-in Operation
When the engine is overhauled, it should be mounted on a dynamometer and operated for break-in and inspection.Starting Up
(1) Before starting the engine, check the levels of coolant, engine oil and fuel, and bleed the fuel and cooling system.(2) With the fuel supply cut off, operate the starter and crank the engine for about 15 seconds to circulate engine oil.(3) Move the speed control lever slightly in the direction for increased fuel (do not move it to "full injection" position), then turn the starter switch key to the [START] position to start
Fuel system bleeding(1) Loosen the air vent plug on the fuel filter. (approx. 1.5 turns)(2) Move the priming button for the filter up and down.(3) When fuel flowing from the vent hole no longer contains air bubbles, tighten the vent plug.Inspection and Adjustment of No-Load Minimum (Low Idling) Speed and Maximum Speed
(a) The following adjustments were inspected and set for each engine on the test bench at the factory, and the set bolts are sealed. These settings should be checked and adjusted only at our designated service shop.(b) After the governor parts are adjusted, all external stoppers must be sealed in the same way as when adjustments were made at the factory.(c) Whether the seals are intact or not has important bearing on the validity of claims under warranty. Be sure to seal all the specified sections.(d) When inspecting or adjusting, be ready to operate the engine stop lever manually in case the engine overruns (engine operation at extremely high speed).
Prior to inspection and adjustment, conduct a warm-up operation until the coolant and oil temperatures rise above 70 °C [158 °F].(1) Starting the engine
Inspection and adjustment of no-load minimum (low idling) speed and maximum speed(a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch.(b) The engine ignites when the rotation speed reaches approximately 150 min-1, and the engine speed rises. Operate the speed control lever to maintain the engine speed between 800 and 1000 min-1.(c) After the engine speed stabilizes, return the speed control lever to the low idling position.(2) Low idling setting (no-load minimum rotation speed setting)Hold the speed control lever at the position of no-load minimum rotation speed, then secure the lever in that position using the idling adjustment screw.
If there is speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range.
(3) Governor setting (maximum rotation speed setting)(a) Keep the speed control lever at the position of the specified maximum rotation speed.(b) With the speed control lever held in that position, adjust and set the governor set bolt (maximum rotation speed set screw) to the specified rotation speed).Inspection of V-Belt Tension
(1) Press the V-belt at a midpoint between the alternator and crankshaft pulley to check the mount of belt deflection.
Inspection of V-belt tension (2) If the amount of belt deflection does not conform to the standard value, loosen the adjusting bolt and move the alternator to adjust the belt tension.Engine Break-in Operation
When the engine is overhauled, it should be mounted on a dynamometer and operated for break-in and inspection.Starting Up
(1) Before starting the engine, check the levels of coolant, engine oil and fuel, and bleed the fuel and cooling system.(2) With the fuel supply cut off, operate the starter and crank the engine for about 15 seconds to circulate engine oil.(3) Move the speed control lever slightly in the direction for increased fuel (do not move it to "full injection" position), then turn the starter switch key to the [START] position to start