108622-3230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223230 220801610a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108622-3230 1086223230

HINO 220801610A 220801610a

Cross reference number

ZEXEL 108622-3230 1086223230

HINO 220801610A 220801610a

Zexel num

Bosch num

Firm num

Name

108622-3230
108622-3231

220801610A HINO

INJECTION-PUMP ASSEMBLY
P09C * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-1520

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 21

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 9.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 161 159 163

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 43.3 43.3

Boost pressure mmHg 325 325

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

Injection quantity adjustment_02

Adjusting point B

Rack position 9.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 167 164 170

Fixing the lever *

Boost pressure kPa 43.3 43.3

Boost pressure mmHg 325 325

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_03

Adjusting point D

Rack position 10

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 165 162 168

Fixing the lever *

Boost pressure kPa 43.3 43.3

Boost pressure mmHg 325 325

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_04

Adjusting point E

Rack position 9.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 145.5 142.5 148.5

Fixing the lever *

Boost pressure kPa 43.3 43.3

Boost pressure mmHg 325 325

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_05

Adjusting point G

Rack position 4+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 11.5 8.5 14.5

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

Injection quantity adjustment_06

Adjusting point H

Rack position 7.6

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 122.5 119.5 125.5

Fixing the lever *

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

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 120 140

Fixing the lever *

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

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 7.6

Boost pressure kPa 9.3 7.3 9.3

Boost pressure mmHg 70 55 70

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 9.5

Boost pressure kPa 30 30 30

Boost pressure mmHg 225 225 225

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 5 4.5 5.5

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 4 3.95 4.05

Output voltage V 2.6 2.6 2.61

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.35 6.45

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

Pre-stroke mm 3.4

Output voltage V 3 2.98 3

Confirmation *

_06

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: +-0.05 (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). (5)Stop lever setting: R2 (6)RACK LIMIT: RAL (7)Boost compensator stroke: BCL (8)Damper spring setting (9)Variable speed specification: idling adjustment (10)Main spring setting
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RT=1 TH=2.3mm N1=350r/min R1=4mm N2=1075r/min Q1=3 mm3/st R2=12.9+0.2mm RAL=10.3+-0.1mm BCL=1.9+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa (3)Stopper bolt setting
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aa=130mm
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a=7.5deg+-5deg b=(15deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=56mm
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a=25deg+-5deg b=33deg+-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.
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aa=33mm bb=12.9+0.2mm
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a=30deg+-5deg b=43deg+-5deg

0000001201

(1)Variable speed specification (2)Minimum - maximum speed specification (3)Use the hole at R = aa
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aa=150mm
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a=(17deg)+-5deg b=(33deg)

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(40deg)

0000001901

(A): Pre-stroke actuator (B): Stamp housings A and B at the same time. (C): Stamping range 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (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 counterclockwise 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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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)
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L=33.5+-0.1mm N1=1075r/min Ra=10mm
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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.
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N1=500r/min N2=(720)r/min N3=(910)r/min N4=1075r/min RF=9.5mm Dr1=0.5mm Dr2=0+0.3mm
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0000002401 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
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L=1~2mm
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