Information injection-pump assembly
ZEXEL
108622-3720
1086223720
HINO
220401340A
220401340a
Rating:
Service parts 108622-3720 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-3080A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/27.5{280}
14.
NOZZLE
Include in #1:
108622-3720
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3720
1086223720
HINO
220401340A
220401340a
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
134424-4120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
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
Rack position
(14.1)
Vist
V
1.73
1.73
1.73
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
214
212
216
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(6.7)
Vist
V
2.9
2.8
3
Pump speed
r/min
320
320
320
Average injection quantity
mm3/st.
17
14
20
Max. variation between cylinders
%
0
-15
15
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
0000001201
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=32.5deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=32.5deg+-5deg b=37deg+-5deg
0000000901
(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=(40deg)
----------
aa=6.4+-0.03mm
----------
a=(40deg)
0000001501
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.
----------
----------
----------
----------
0000001701
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 19 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
----------
Information:
Start By:a. remove timing gear case cover1. Put the No. 1 piston at top dead center on the compression stroke. Be sure all the timing marks are in alignment with each other. 2. Remove plate (2) that holds idler gear (1). 3. Remove idler gear (1). 4. Inspect two bushings (3) in idler gear (1). See Engine Specifications for bushing diameter. Remove two bushings (3) if replacement is necessary. 5. Remove fuel injection pump drive gear (4). 6. Bend lock (5) away from the bolt. Remove the bolt and remove washer (6). 7. Remove camshaft drive gear (7) with tool (A).Install Timing Gears
1. Align the slot in gear (1) with the key in the camshaft. Put the camshaft gear in position on the camshaft. 2. Install washer (2), lock (3) and the bolt. Tighten the bolt to a torque of 60-70 N m (45-52 lb ft). Bend the tab of the lock against the bolt head. 3. Align the roll pin in fuel injection pump drive gear (4) with the hole in fuel injection pump drive shaft (5). Install fuel injection pump drive gear (4) on to fuel injection pump drive shaft (5). 4. Install three bolts (6) to hold drive gear (4) to the fuel injection pump drive shaft. 5. Use tool (A) to install two bushings (7) into idler gear (8). Install the bushings even with the outside of idler gear (8). 6. Align the timing marks on idler gear (8) with the crankshaft gear, camshaft drive gear and the fuel injection pump drive gear. 7. Install plate (9) and the bolts to hold idler gear (8) on the idler gear shaft. Tighten the three bolts to a torque of 40 N m (30 lb ft). 8. Check the idler gear end clearance. The clearance must be at least 0.25 mm (.010 in). 9. Fasten a steel plate to the timing gear case. Fasten tooling (A) to the plate as shown. Check the timing gear backlash. The backlash must be 0.08 - 0.15 mm (.003 - .006 in).
1. Align the slot in gear (1) with the key in the camshaft. Put the camshaft gear in position on the camshaft. 2. Install washer (2), lock (3) and the bolt. Tighten the bolt to a torque of 60-70 N m (45-52 lb ft). Bend the tab of the lock against the bolt head. 3. Align the roll pin in fuel injection pump drive gear (4) with the hole in fuel injection pump drive shaft (5). Install fuel injection pump drive gear (4) on to fuel injection pump drive shaft (5). 4. Install three bolts (6) to hold drive gear (4) to the fuel injection pump drive shaft. 5. Use tool (A) to install two bushings (7) into idler gear (8). Install the bushings even with the outside of idler gear (8). 6. Align the timing marks on idler gear (8) with the crankshaft gear, camshaft drive gear and the fuel injection pump drive gear. 7. Install plate (9) and the bolts to hold idler gear (8) on the idler gear shaft. Tighten the three bolts to a torque of 40 N m (30 lb ft). 8. Check the idler gear end clearance. The clearance must be at least 0.25 mm (.010 in). 9. Fasten a steel plate to the timing gear case. Fasten tooling (A) to the plate as shown. Check the timing gear backlash. The backlash must be 0.08 - 0.15 mm (.003 - .006 in).