108822-3220 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088223220 220009990a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108822-3220 1088223220

HINO 220009990A 220009990a

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Cross reference number

ZEXEL 108822-3220 1088223220

HINO 220009990A 220009990a

Zexel num

Bosch num

Firm num

Name

108822-3220
108822-3221

220009990A HINO

INJECTION-PUMP ASSEMBLY
YJ43 * K

Calibration Data:

Adjustment conditions

Test oil
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

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. 41

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-6-2- 7-5-4-3

Pre-stroke mm 7.2 7.17 7.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (12.5)

Vist V 1.97 1.97 1.97

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 146 150

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4.8+-0.0 5

Injection quantity adjustment_02

Rack position (6.3)

Vist V 2.9 2.8 3

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 14.3 13.3 15.3

Max. variation between cylinders % 0 -10 10

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 7.1+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

0000001201

Pre-stroke mm 7.2 7.17 7.23

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 3.2 3.15 3.25

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 7.2 7.17 7.23

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
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
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aa=20mm bb=1mm
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a=37deg+-5deg b=2.5deg+-5deg

0000000901

(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 damper to align with the pointer's groove. (4)Damper (5)Pointer (6)Pre-stroke: aa (7)-
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aa=7.2+-0.03mm
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a=(80deg)

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.
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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.
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Information:

Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal
Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 2. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Replace tie bolt (6) with the temporary bolt (9) that is provided in the service kit.Note: The temporary bolt that is provided in the kit has an undersized bolt head. The temporary bolt prevents the body of the HEUI pump from separating during service. Do not remove the temporary bolt until the fuel transfer pump has been completely reinstalled.
Tighten the temporary bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the temporary bolt. The aluminum housing of the pump could be damaged.
After installing the temporary bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Temporary bolt (10) Seals (11) Seal
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.Installing the Fuel Transfer Pump onto the HEUI Pump
Illustration 4 g01458639
(1) HEUI pump (10) 239-2402 Seals
Install the three new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 5 g01470031
(2) Fuel transfer pump (11) 179-8128 Seal
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 6 g01132969
Do not remove the temporary bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Illustration 7 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for temporary bolt (12) 185-3241 O-Ring Seal
Install the three mounting bolts (7) for the fuel transfer pump (2).