Information injection-pump assembly
ZEXEL
108622-3450
1086223450
HINO
220008821A
220008821a
Rating:
Service parts 108622-3450 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2781A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/23.5{240}
14.
NOZZLE
Include in #1:
108622-3450
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3450
1086223450
HINO
220008821A
220008821a
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)
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
10.8
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
185.5
183.5
187.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.3
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
199
196
202
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.3+-0.
5
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
203
197
209
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
260
255
265
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
Rack limit
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_05
Adjusting point
E
Rack position
3.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.5
5.5
11.5
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
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
8.95
Boost pressure
kPa
26.7
26.7
28.7
Boost pressure
mmHg
200
200
215
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
10.8
Boost pressure
kPa
42
42
42
Boost pressure
mmHg
315
315
315
Boost compensator adjustment_03
Pump speed
r/min
300
300
300
Rack position
(12.4)
Boost pressure
kPa
58
58
58
Boost pressure
mmHg
435
435
435
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
2.35
2.45
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)Tolerance for racks not indicated: +-0.05mm.
(2)Torque spring does not operate.
(3)Stop lever setting: STL
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Damper spring setting
(7)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 prestroke at this time must be Pr1 (Pv1).
************
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STL=(13.1)+0.5mm BCL=(3.45)mm N1=325r/min R1=3.8mm N2=1000r/min Q1=3 mm3/st Pr1=4+-0.05mm Pv1=2.2+-0.01V
----------
----------
STL=(13.1)+0.5mm BCL=(3.45)mm N1=325r/min R1=3.8mm N2=1000r/min Q1=3 mm3/st Pr1=4+-0.05mm Pv1=2.2+-0.01V
----------
Speed control lever angle
F:Full speed
----------
----------
a=(14.5deg)+-5deg
----------
----------
a=(14.5deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=45mm
----------
a=26deg+-5deg b=36.5deg+-3deg
----------
aa=45mm
----------
a=26deg+-5deg b=36.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Rack position bb
(3)Before governor adjustment, set the stopper screw and apply red paint to it.
----------
aa=33mm bb=(13.1)+0.5mm
----------
a=36deg+-5deg b=44deg+-5deg
----------
aa=33mm bb=(13.1)+0.5mm
----------
a=36deg+-5deg b=44deg+-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=(0deg)
----------
aa=6.4+-0.03mm
----------
a=(0deg)
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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----------
----------
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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
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=1000r/min Ra=11.3mm
----------
----------
L=33.5+-0.1mm N1=1000r/min Ra=11.3mm
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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=(665)r/min N3=(755)r/min N4=1000r/min RF=10.8mm Dr1=0.5mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=(665)r/min N3=(755)r/min N4=1000r/min RF=10.8mm Dr1=0.5mm Dr2=0+0.3mm
----------
Information:
2. Turn the crankshaft until two of the pistons are at bottom center. Remove the nuts and bolts (1) from the connecting rods that are at bottom center. Remove connecting rod caps (2). Put identification marks on them for installation purposes.
Do not let the connecting rods hit the crankshaft or the bottom edge of the cylinder liners when the pistons are removed.
3. Push the connecting rods and pistons away from the crankshaft until the piston rings are out of the cylinder liners. Remove the two pistons from the engine.4. Keep each connecting rod cap with its respective connecting rod and piston. Put identification marks on each piston as to its location in the engine.5. Do Steps 1 through 4 for the removal of the remaining pistons.Install Pistons & Connecting Rods
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and the connecting rod bearings.3. Move the piston rings on the pistons until the ring openings are approximately 90° apart. 4. Put the piston in the cylinder liner with the "V" mark on the piston in alignment with the "V" mark on the cylinder block. Put Tool (A) in position on the cylinder block and compress the piston rings.5. Push the piston into the cylinder liner and out of the ring compressor. 6. Pull the connecting rod into position on the crankshaft as shown. Install connecting rod bolts (1) in the connecting rods.7. Put clean engine oil on the lower half of the connecting rod bearing. Put 2P2506 Thread Lubricant on the bolt threads and on the surfaces of the nuts that make contact with the connecting rod caps.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
8. Install connecting rod caps (2) and the nuts that hold them. Tighten the nuts to a torque of 40 4 N m (30 3 lb ft). Put a mark on each nut as to its location. Tighten them 90° 5° more.9. Do Steps 1 through 8 for the remainder of the pistons.End By:a. install oil pumpb. install oil pan platec. install cylinder head assembly and spacer plateDisassemble Pistons & Connecting Rods
Start By:a. remove pistons and connecting rods 1. Remove the rings from the pistons with Tool (A). 2. Remove retaining ring (3), piston pin (1) and connecting rod (2) from the piston.3. Remove the bearings from the crankshaft end of the connecting rod.4. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295-02 for more information about removal and installation of piston pin bearings. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 176
Do not let the connecting rods hit the crankshaft or the bottom edge of the cylinder liners when the pistons are removed.
3. Push the connecting rods and pistons away from the crankshaft until the piston rings are out of the cylinder liners. Remove the two pistons from the engine.4. Keep each connecting rod cap with its respective connecting rod and piston. Put identification marks on each piston as to its location in the engine.5. Do Steps 1 through 4 for the removal of the remaining pistons.Install Pistons & Connecting Rods
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and the connecting rod bearings.3. Move the piston rings on the pistons until the ring openings are approximately 90° apart. 4. Put the piston in the cylinder liner with the "V" mark on the piston in alignment with the "V" mark on the cylinder block. Put Tool (A) in position on the cylinder block and compress the piston rings.5. Push the piston into the cylinder liner and out of the ring compressor. 6. Pull the connecting rod into position on the crankshaft as shown. Install connecting rod bolts (1) in the connecting rods.7. Put clean engine oil on the lower half of the connecting rod bearing. Put 2P2506 Thread Lubricant on the bolt threads and on the surfaces of the nuts that make contact with the connecting rod caps.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
8. Install connecting rod caps (2) and the nuts that hold them. Tighten the nuts to a torque of 40 4 N m (30 3 lb ft). Put a mark on each nut as to its location. Tighten them 90° 5° more.9. Do Steps 1 through 8 for the remainder of the pistons.End By:a. install oil pumpb. install oil pan platec. install cylinder head assembly and spacer plateDisassemble Pistons & Connecting Rods
Start By:a. remove pistons and connecting rods 1. Remove the rings from the pistons with Tool (A). 2. Remove retaining ring (3), piston pin (1) and connecting rod (2) from the piston.3. Remove the bearings from the crankshaft end of the connecting rod.4. See Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295-02 for more information about removal and installation of piston pin bearings. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 176