108622-3561 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223561


108622-3561 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108622-3561 1086223561

Cross reference number

ZEXEL 108622-3561 1086223561


Zexel num
Bosch num
Firm num
Name
108622-3561 
 
   
INJECTION-PUMP ASSEMBLY

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   134424-1420
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.   31
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
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   11
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   191.5 189.5 193.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Injection quantity adjustment_02
Adjusting point   B
Rack position   11.15
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   199 193 205
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Injection quantity adjustment_03
Adjusting point   C
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   250 245 255
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
Rack limit   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Injection quantity adjustment_04
Adjusting point   -
Rack position   4.7+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   14 11 17
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
 
Injection quantity adjustment_05
Adjusting point   F
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   110 110
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R1(8)
Boost pressure kPa   8 8 10
Boost pressure mmHg   60 60 75
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   11
Boost pressure kPa   77.3 77.3 77.3
Boost pressure mmHg   580 580 580
0000001601
Pre-stroke mm   6.4 6.37 6.43
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   4 3.95 4.05
Output voltage V   2.45 2.44 2.46
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
 
_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

Test data 108622-3561
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (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). The pre-stroke at that time must be Pr1 (Pv1). (5)Stop lever setting: R2 (6)RACK LIMIT (7)Damper spring setting (8)Boost compensator stroke: BCL (9)Variable speed specification: idling adjustment (10)Main spring setting
----------
RT=1 TH=2.4mm N1=350r/min R1=4.1mm N2=1000r/min Q1=3mm3/st Pr1=4+-0.05mm Pv1=2.45+-0.01V R2=12.6+0.5mmmm BCL=(3)+-0.1mm
----------

Speed control lever angle

Test data 108622-3561
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=130mm
----------
a=(1deg)+-5deg a=(16.5deg)+-5deg

0000000901

Test data 108622-3561
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 108622-3561
N:Pump normal S:Stop the pump. (1)Set stopper screw so that rack position = aa (after setting, apply red paint). (2)Use the hole at R = bb
----------
aa=12.6+0.5mm bb=35mm
----------
a=40deg+-5deg b=43deg+-5deg

0000001201

Test data 108622-3561
(1)Minimum - maximum speed specification (2)Variable speed specification (3)Use the hole at R = aa
----------
aa=112mm
----------
a=(15deg) b=(16deg)+-5deg

0000001301

Test data 108622-3561
(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=(1deg)

0000001901

Test data 108622-3561
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

Test data 108622-3561
(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=11.15mm
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0000002301 LEVER

Test data 108622-3561
(a) Speed lever (b) Two step changeover lever (c) Nut (d) Shaft (e) Load lever (f) Pin (g) Load lever Instructions for adjusting the RED governor's 2 stage changeover lever. 1. Minimum-maximum speed specification adjustment (1)Move the 2-stage changeover lever (b) until the speed lever (a) contacts the full stopper bolt. (2)Move the load lever (e) as far as the idling position, and fix. (3)Adjust nut (c) so that the right hand end of the shaft (d) under the 2-stage changeover lever (b) is in a position L1 from the pin (f) in the center of the load lever (e). 2. Variable speed specification adjustment (1)Move the 2-stage changeover lever until the load lever (e) contacts the full load stopper bolt. (2)Check that the speed lever (a) operates between the idling and the full speed position.
----------
L1=5~10mm
----------
R1=112mm R2=130mm R3=45mm a1=(16.5deg)+-5deg a2=(16deg)+-5deg a3=25deg+-5deg

0000002401 GOVERNOR TORQUE CONTROL

Test data 108622-3561
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=(750)r/min N3=(775)r/min N4=1000r/min RF=11mm Dr1=0.15mm Dr2=0+0.3mm
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Group cross 108622-3561 ZEXEL

Hino 

 
220801780A 
INJECTION-PUMP ASSEMBLY
K-3
108622-3561  
 
 
INJECTION-PUMP ASSEMBLY

Hino 

 
220801781A 
INJECTION-PUMP ASSEMBLY
K-3
 
220801781B 
INJECTION-PUMP ASSEMBLY
K-3
9 400 619 187 
220801781C 
INJECTION-PUMP ASSEMBLY
K-3
9 400 619 187 
S220801781 
INJECTION-PUMP ASSEMBLY
K-3
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