108622-3941 ZEXEL 9 400 619 210 BOSCH INJECTION-PUMP ASSEMBLY 9400619210 1086223941 220401880b


108622-3941 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 210 9400619210
ZEXEL 108622-3941 1086223941
HINO 220401880B 220401880b

Cross reference number

BOSCH 9 400 619 210 9400619210
ZEXEL 108622-3941 1086223941
HINO 220401880B 220401880b


Zexel num
Bosch num
Firm num
Name
108622-3941 
9 400 619 210 
220401880B  HINO
INJECTION-PUMP ASSEMBLY
K13C-UK 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)
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   -
Rack position   15.3
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   223 220 226
Max. variation between cylinders %   0 -3 3
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   6+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   11.5 10.5 12.5
Max. variation between cylinders %   0 -10 10
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(15.3)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   223 221 225
Basic   *
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
PS407980-224* V   2.2+-0.0 1
PS407980-224* mm   4+-0.05
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   199 193 205
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
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   R2-3.3
Boost pressure kPa   20 17.3 22.7
Boost pressure mmHg   150 130 170
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-1. 3)
Boost pressure kPa   49.3 49.3 49.3
Boost pressure mmHg   370 370 370
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 108622-3941
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=AG56 BCL=3.3+-0.1mm
----------

Speed control lever angle

Test data 108622-3941
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=36deg+-5deg b=37.5deg+-3deg

Stop lever angle

Test data 108622-3941
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Set the stopper screw. (After setting, apply red paint.) (3)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever. (4)Use the hole above R = cc
----------
aa=0r/min bb=0.5+-0.3mm cc=25mm
----------
a=20deg+-5deg b=45deg+-5deg

0000001301

Test data 108622-3941
(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=(10deg)

0000001901

Test data 108622-3941
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 108622-3941
(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 (-2320) 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)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V). (5)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 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=1000r/min Ra=R1(15.3)+0.5mm
----------

0000002301 ACS

Test data 108622-3941
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Lever 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. (2)Select C so that dimension L2 can be obtained. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Set to full boost. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+0.5)mm Rb=R3-0.2mm Rc=R3-1.2mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=84.5+-2.7kPa(634+-20mmHg) P3=57.7+-0.7kPa(433+-5mmHg) Q1=119+-6cm3/1000st Q2=193.5+-10cm3/1000st Q3=170+-10cm3/1000st




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Group cross 108622-3941 ZEXEL

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