Information injection-pump assembly
ZEXEL
108622-3391
1086223391
HINO
220008771A
220008771a
Rating:
Service parts 108622-3391 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2770B
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/27.5{280}
14.
NOZZLE
Include in #1:
108622-3391
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3391
1086223391
HINO
220008771A
220008771a
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
105780-8250
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
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
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.
33
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
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
9.8
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
133.5
131.5
135.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.6
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
144.5
141.5
147.5
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.85
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
136
133
139
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
178
173
183
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
Rack limit
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_05
Adjusting point
F
Rack position
4.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
10.5
7.5
13.5
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_06
Adjusting point
H
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
130
150
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
8.95
Boost pressure
kPa
9.3
9.3
11.3
Boost pressure
mmHg
70
70
85
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
9.8
Boost pressure
kPa
25.3
25.3
25.3
Boost pressure
mmHg
190
190
190
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.
11.5
11
12
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
2.4
2.37
2.43
Output voltage
V
2.95
2.94
2.96
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
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: +-0.05mm.
(4)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). The pre-stroke at that time must be Pr1 (Pv1).
(5)Stop lever setting: R2
(6)RACK LIMIT
(7)Boost compensator stroke: BCL
(8)Damper spring setting
----------
RT=1 TH=2.3mm N1=300r/min R1=4.8mm N2=1075r/min Q1=5mm3/ST Pr1=4+-0.05mm Pv1=2.2+-0.01V R2=12.6+0.5mm BCL=(0.85)mm
----------
----------
RT=1 TH=2.3mm N1=300r/min R1=4.8mm N2=1075r/min Q1=5mm3/ST Pr1=4+-0.05mm Pv1=2.2+-0.01V R2=12.6+0.5mm BCL=(0.85)mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=14deg+-5deg
----------
----------
a=14deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=56mm
----------
a=22deg+-5deg b=32deg+-3deg
----------
aa=56mm
----------
a=22deg+-5deg b=32deg+-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=33mm bb=12.6+0.5mm
----------
a=36deg+-5deg b=(42deg)+-5deg
----------
aa=33mm bb=12.6+0.5mm
----------
a=36deg+-5deg b=(42deg)+-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=(50deg)
----------
aa=6.4+-0.03mm
----------
a=(50deg)
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
Adjustment of the rack sensor (-0720)
1. Rack limit adjustment
(1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position.
(2)Install the rod (E) to the block (C).
(3)At the rack limit, set the distance between the pump end face and the rod (E) to L1.
2. Rack sensor
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at N1.
(3)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.)
(4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
----------
L=33.5+-0.1mm N1=550r/min Ra=9.8mm
----------
----------
L=33.5+-0.1mm N1=550r/min Ra=9.8mm
----------
0000002301 GOVERNOR TORQUE CONTROL
Dr:Torque control stroke
(A): Without torque control spring capsule
1. Adjustment procedures
(1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting.
2. Procedures for adjustment
(1)Remove the torque control spring capsule.
(2)Operate the pump at approximately N1. (End of idling spring operation < N1.)
(3)Tilt the lever to the full side.
(4)Set so that R = RF.
(5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window.
(6)Adjust so that the torque control stroke Dr1 can be obtained.
(7)Align N2 and N3 with the torque control spring capsule.
3. Final confirmation
(1)After final confirmation, temporarily set the load lever to N = N1, R = idling position.
(2)From this condition, increase speed to N = N4.
(3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=(890)r/min N3=(1050)r/min N4=1075r/min RF=9.8mm Dr1=0.8mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=(890)r/min N3=(1050)r/min N4=1075r/min RF=9.8mm Dr1=0.8mm Dr2=0+0.3mm
----------
Information:
(1) Crossbar (from 8B7548 Puller).(2) Spacer plate.(3) S1589 Bolt with two 1S379 Washers.(4) 1D4595 Bolt.(5) 3H465 Plate.(6) 1P2403 Dial Indicator.(7) 1P2394 Adapter Plate.(8) 1P2402 Gauge Body.Make reference to Cylinder Liner Projection in Testing and Adjusting for the complete procedure.1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten bolts (3) evenly in four steps: 1st step ... 14 N m (10 lb ft)2nd step ... 35 N m (25 lb ft) 3rd step ... 70 N m (50 lb ft)4th step ... 95 N m (70 lb ft)2. Install tools as shown. Tighten bolts (4) evenly in four steps: 1st step ... 7 N m (5 lb ft)2nd step ... 20 N m (15 lb ft)3rd step ... 35 N m (25 lb ft)4th step ... 70 N m (50 lb ft)3. Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area. Cylinder liner projection measurements for any cylinder liner must be ... 0.033 to 0.175 mm (.0013 to .0069 in)Maximum permissible difference between all four measurements ... 0.05 mm (.002 in)Maximum permissible difference between average projection of any two cylinder liners next to each other ... 0.05 mm (.002 in)Maximum permissible difference between average projection of all cylinder liners under one cylinder head ... 0.10 mm (.004 in) If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to special Instruction, Form No. FMO55228 for complete instructions on the use of 8S3140 Counterboring Tool Arrangement. 4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.75 mm (.030 in) Maximum permissible depth to machine counterbore to adjust cylinder liner projection ... 1.14 mm (.045 in)Install a 0.76 mm (.030 in) shim plus any added shims necessary to get the correct cylinder liner projection. Be sure that the 0.75 mm (.030 in) shim is directly under the cylinder liner flange.