108622-3821 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086223821 220401661a


108622-3821 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 108622-3821 1086223821
HINO 220401661A 220401661a

Cross reference number

ZEXEL 108622-3821 1086223821
HINO 220401661A 220401661a


Zexel num
Bosch num
Firm num
Name
108622-3821 
108622-3822 
 
220401661A  HINO
INJECTION-PUMP ASSEMBLY
P11C * 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
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   33
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   -
Rack position   14.8
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   172 169 175
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
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   7.7+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   15 14 16
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
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(14.8)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   172 170 174
Basic   *
Fixing the lever   *
Boost pressure kPa   57.3 57.3
Boost pressure mmHg   430 430
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.3
Pump speed r/min   1075 1075 1075
Average injection quantity mm3/st.   150.5 144.5 156.5
Fixing the lever   *
Boost pressure kPa   57.3 57.3
Boost pressure mmHg   430 430
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-1.6
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   125.5 119.5 131.5
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-1.6
Boost pressure kPa   32 30.7 33.3
Boost pressure mmHg   240 230 250
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2[R1-1. 55]
Boost pressure kPa   44 44 44
Boost pressure mmHg   330 330 330
0000001601
Pre-stroke mm   6.4 6.37 6.43
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   11.5 11 12
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   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
 
_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

Test data 108622-3821
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
T1=AG29 BCL=1.6+-0.1mm
----------

Speed control lever angle

Test data 108622-3821
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=49.5mm
----------
a=35deg+-3deg b=19deg+-5deg

Stop lever angle

Test data 108622-3821
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = approximately aa. (2)At pump speed bb and rack position cc, set the stopper bolt. (3)Use the hole above R = dd
----------
aa=19.3mm bb=0r/min cc=2.9+-0.3mm dd=35mm
----------
a=20deg+-5deg b=34deg+-5deg

0000001301

Test data 108622-3821
(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=(50deg)

0000001901

Test data 108622-3821
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 108622-3821
(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=1075r/min Ra=R1(14.8)+0.3mm
----------

0000002301 AIR CYLINDER

Test data 108622-3821
1. Air cylinder adjustment procedure (1)Set the speed lever at idle. (2)Temporarily set the clearance between the air cylinder (C) and the set bolt (B) to L1. (3)Set the speed at N. (4)Apply positive pressure P1 to the air cylinder (C). (5)Gradually push out the set bolt (B). (6)Tighten the nut (D) at the point where the rack position is Ra at speed N. (7)Apply positive pressure P1 several times. (8)Confirm that the lever returns to the idle position at positive pressure P2.
----------
L=(6)mm N=320r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=7.7+-0.1mm
----------




Have questions with 108622-3821?





Group cross 108622-3821 ZEXEL

Hino 

 
220401620A 
INJECTION-PUMP ASSEMBLY
P11C
 
 
INJECTION-PUMP ASSEMBLY

Hino 

 
220401621A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 611 216 
220401621C 
INJECTION-PUMP ASSEMBLY
P11C
9 400 611 807 
220401621G 
INJECTION-PUMP ASSEMBLY
P11C
 
220401621H 
INJECTION-PUMP ASSEMBLY
P11C
9 400 612 555 
220401621J 
INJECTION-PUMP ASSEMBLY
P11C
F 01G 09U 0FX 
220401630A 
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K13U-B
9 400 611 967 
220401630B 
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K13U-B
 
220401660A 
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108622-3821  

108622-3822 
 
220401661A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 202 
220401662A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 611 210 
220401690A 
INJECTION-PUMP ASSEMBLY
K13D
 
220401690B 
INJECTION-PUMP ASSEMBLY
K13D
9 400 619 203 
220401691A 
INJECTION-PUMP ASSEMBLY
K13D
 
220401710A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 611 734 
220401711A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 611 301 
 
INJECTION-PUMP ASSEMBLY

Hino 

9 400 611 866 
220402081A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 612 245 
220402082A 
INJECTION-PUMP ASSEMBLY
P11C
F 01G 09U 0FY 
220402083A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 204 
220402084A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401720A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 205 
220401721A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401780A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401783A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401784A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 612 322 
220401784B 
INJECTION-PUMP ASSEMBLY
P11C
F 01G 09U 0FZ 
220401785A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 612 597 
220401786A 
INJECTION-PUMP ASSEMBLY
P11C
F 01G 09U 0G0 
220401787A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 206 
220401788A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 206 
S220401788 
INJECTION-PUMP ASSEMBLY
P11C
 
220401790A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401793A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401794A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401794B 
INJECTION-PUMP ASSEMBLY
P11C
 
220401795A 
INJECTION-PUMP ASSEMBLY
P11C
 
220401796A 
INJECTION-PUMP ASSEMBLY
P11C
9 400 619 207 
220401797A 
INJECTION-PUMP ASSEMBLY
P11C
 
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9 400 612 016 
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K13C-UB
9 400 611 867 
220401873A 
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K13C-UB
9 400 611 867 
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K13C-UB
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