Information injection-pump assembly
ZEXEL
108822-3050
1088223050
HINO
220008790A
220008790a
Rating:
Service parts 108822-3050 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
23600-2811A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/23.5{240}
14.
NOZZLE
Include in #1:
108822-3050
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108822-3050
1088223050
HINO
220008790A
220008790a
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
131424-8120
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
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
41
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
1-8-6-2-
7-5-4-3
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 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
15.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
177.5
174.5
180.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
PS407910-303*
V
2.2+-0.0
1
PS407910-303*
mm
4+-0.05
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.5+-0.5
Pump speed
r/min
340
340
340
Average injection quantity
mm3/st.
18.1
15.1
21.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
PS407910-303*
V
V1+0.05+
-0.01
PS407910-303*
mm
6.3+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(15.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
177.5
175.5
179.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
69.3
69.3
Boost pressure
mmHg
520
520
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
PS407910-303*
V
2.2+-0.0
1
PS407910-303*
mm
4+-0.05
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.75
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
154.5
151.5
157.5
Fixing the lever
*
Boost pressure
kPa
69.3
69.3
Boost pressure
mmHg
520
520
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
PS407910-303*
V
2.2+-0.0
1
PS407910-303*
mm
4+-0.05
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-2.5
Boost pressure
kPa
22
22
24
Boost pressure
mmHg
165
165
180
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
35)
Boost pressure
kPa
56
56
56
Boost pressure
mmHg
420
420
420
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
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)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set the stop lever before governor adjustment. [When setting the stop lever after governor adjustment, confirm that Ra can be obtained at the full setting.]
(4)Stop lever's normal position setting: equivalent to RA
(5)Boost compensator stroke: BCL
(6)Damper spring setting
----------
T1=AC66 Ra=R1+1.25mm RA=18mm BCL=2.5+-0.1mm
----------
----------
T1=AC66 Ra=R1+1.25mm RA=18mm BCL=2.5+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=69mm
----------
a=14deg+-5deg b=38deg+-3deg
----------
aa=69mm
----------
a=14deg+-5deg b=38deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At rack position aa, set the stopper bolt (pump speed bb r/min).
(2)Set the stopper bolt (N = 0)
(3)Use the pin above R = cc
----------
aa=1.5+-0.3mm bb=0r/min cc=37mm
----------
a=18deg+-5deg b=35deg+-5deg
----------
aa=1.5+-0.3mm bb=0r/min cc=37mm
----------
a=18deg+-5deg b=35deg+-5deg
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 coupling to align with the pointer's groove.
(4)Coupling
(5)Pointer
(6)Pre-stroke: aa
(7)-
----------
aa=6.4+-0.03mm
----------
a=(80deg)
----------
aa=6.4+-0.03mm
----------
a=(80deg)
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 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=900r/min Ra=R1(15.6)+1.25mm
----------
----------
N1=900r/min Ra=R1(15.6)+1.25mm
----------
Information:
Use the following tests for troubleshooting and repair steps. Use the ""Test for Cylinder Cutout"" in order to determine if the replacement of individual injectors is needed. Replace suspect injectors with the part number of the original injector. Use the ""Test for Leakage from Poppet Valve"" in order to determine if the full set of injectors need to be replaced. For replacement of the full set of injectors, use the current injectors and new software that is listed in Table 2.Test for Cylinder Cutout
The cylinder cutout test should be used in order to determine if an individual injector may have caused the failure.
Warm the engine out of cold mode.
Connect Cat ET to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm 125 rpm. An extremely rough running engine will need to be diagnosed by other methods.
Cut out one bank of cylinders. Note engine rpm and the fuel position on the Cat ET screen at that time.
Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize, and note the fuel position.
Give power back to that cylinder. Allow the engine to stabilize. Note the fuel position.
Repeat steps 5 through 6 until the cylinder bank has been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps 5 through 8.
Repeat steps 4 through 9 with the engine at 2000 rpm.
Compare the results from the fuel position from each cylinder.
If the cylinder was cut out and the fuel position did not change the cylinder may not have been producing power. This cylinder would be suspect.
When you are finished with the test, reduce engine RPM to low idle. Shut off the engine.
Replace any suspect injector with a similar original injector. Install new seals for the injector and the jumper tube during this repair. The repair procedure for the injector is found in Special Instruction, REHS0116.It is possible that multiple injectors are functioning improperly. Complete ""Test for Leakage from Poppet Valve"" in order to evaluate possible excessive leakage from the injectors.Test for Leakage from Poppet Valve
Warm the engine out of Cold Mode to normal operating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation in order to observe the injectors. Leave the covers in place.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with no load.
Use Cat ET in order to perform the test that overrides the injection actuation system. Increase injection actuation pressure to the maximum value.
Observe all of the injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable. However, a continuous stream of oil is an indication of excessive leakage of the poppet valve. Only leaks at the spill port are an indication of excessive leakage from the poppet valve.
If multiple injectors display excessive leakage from the poppet valves, update the set of injectors with
The cylinder cutout test should be used in order to determine if an individual injector may have caused the failure.
Warm the engine out of cold mode.
Connect Cat ET to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm 125 rpm. An extremely rough running engine will need to be diagnosed by other methods.
Cut out one bank of cylinders. Note engine rpm and the fuel position on the Cat ET screen at that time.
Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize, and note the fuel position.
Give power back to that cylinder. Allow the engine to stabilize. Note the fuel position.
Repeat steps 5 through 6 until the cylinder bank has been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps 5 through 8.
Repeat steps 4 through 9 with the engine at 2000 rpm.
Compare the results from the fuel position from each cylinder.
If the cylinder was cut out and the fuel position did not change the cylinder may not have been producing power. This cylinder would be suspect.
When you are finished with the test, reduce engine RPM to low idle. Shut off the engine.
Replace any suspect injector with a similar original injector. Install new seals for the injector and the jumper tube during this repair. The repair procedure for the injector is found in Special Instruction, REHS0116.It is possible that multiple injectors are functioning improperly. Complete ""Test for Leakage from Poppet Valve"" in order to evaluate possible excessive leakage from the injectors.Test for Leakage from Poppet Valve
Warm the engine out of Cold Mode to normal operating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation in order to observe the injectors. Leave the covers in place.
Hot oil and components can cause personal injury.Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with no load.
Use Cat ET in order to perform the test that overrides the injection actuation system. Increase injection actuation pressure to the maximum value.
Observe all of the injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable. However, a continuous stream of oil is an indication of excessive leakage of the poppet valve. Only leaks at the spill port are an indication of excessive leakage from the poppet valve.
If multiple injectors display excessive leakage from the poppet valves, update the set of injectors with