Rating:
Information injection-pump assembly
ZEXEL
108622-3570
1086223570
HINO
220009550A
220009550a
Cross reference number
ZEXEL
108622-3570
1086223570
HINO
220009550A
220009550a
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
134424-1520
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
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.
26
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
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
Adjusting point
-
Rack position
11.2
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
124
121
127
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.62+-0.
01
PS407980-224*
mm
4+-0.05
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8.5
5.5
11.5
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
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(11.2)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
124
122
126
Basic
*
Fixing the lever
*
PS407980-224*
V
2.62+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.25
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
140
134
146
Fixing the lever
*
PS407980-224*
V
2.62+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
190
190
210
Fixing the lever
*
Rack limit
*
PS407980-224*
V
2.62+-0.
01
PS407980-224*
mm
4+-0.05
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.
5
4.5
5.5
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
4
3.95
4.05
Output voltage
V
2.62
2.61
2.63
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
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)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
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T1=J19
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T1=J19
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Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
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aa=47mm
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a=18.5deg+-5deg b=44.5deg+-3deg
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aa=47mm
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a=18.5deg+-5deg b=44.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)With the speed lever in the full position at speed = bb, set the stopper screw so that the rack position = cc. After adjustment, apply red paint.
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aa=40mm bb=1150r/min cc=4.2-0.5mm
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a=31deg+-5deg b=37.5deg+-5deg
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aa=40mm bb=1150r/min cc=4.2-0.5mm
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a=31deg+-5deg b=37.5deg+-5deg
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=(0deg)
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aa=6.4+-0.03mm
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a=(0deg)
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
1. Rack limit adjustment
(1)Mount the joint (B).
(2)Select the shim (D) so that the rack limit's rack position is obtained at that time.
(3)Install the rod (E) to the block (C).
The distance between the pump end face and the rod (E) at rack limit must be L.
2. Rack sensor adjustment (-0020)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set at speed N.
(4)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.)
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(6)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)
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L=38-0.2mm N=1075r/min Ra=R1(11.2)+1.25mm
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L=38-0.2mm N=1075r/min Ra=R1(11.2)+1.25mm
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0000002301 AIR CYLINDER
Adjustment of the air cylinder
1. Set the speed lever at the idling position.
2. Set the gap between the air cylinder (a) and the set bolt (b) to L1.
3. Set the speed at N1, apply positive pressure P1 to the air cylinder (a) and read the rack position.
4. Push set bolt (b) out and tighten nut (c) at N1 when the rack position is R1.
5. Apply positive pressure several times and confirm that the lever returns to the idle position at positive pressure P2.
6. Confirm that the rack position is R1 at positive pressure P1.
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L1=(8)mm R1=7+-0.1mm N1=290r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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L1=(8)mm R1=7+-0.1mm N1=290r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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