108822-3003 ZEXEL 9 400 619 746 BOSCH INJECTION-PUMP ASSEMBLY 9400619746 1088223003 220008103a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 746 9400619746

ZEXEL 108822-3003 1088223003

HINO 220008103A 220008103a

Service parts 108822-3003 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3020

3. GOVERNOR 105489-4103

4. SUPPLY PUMP 105237-4490

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0960

7. COUPLING PLATE 156638-5422

8. _ 159590-7120

9. _

10. NOZZLE AND HOLDER ASSY 105101-7502

11. Nozzle and Holder 236002540B

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/23.5{240}

13. NOZZLE-HOLDER 105030-3620

14. NOZZLE

15. NOZZLE SET 105019-0200

Include in #1:

108822-3003 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 746 9400619746

ZEXEL 108822-3003 1088223003

HINO 220008103A 220008103a

Zexel num

Bosch num

Firm num

Name

108822-3003
108822-3004

9 400 619 746

220008103A HINO

INJECTION-PUMP ASSEMBLY
FT-2 * 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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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. 42

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-6-2- 7-5-4-3

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 209 207 211

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 212 209 215

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_03

Adjusting point C

Rack position 10.05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 212 209 215

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 125 145

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

Injection quantity adjustment_05

Adjusting point G

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.5 9.5 15.5

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

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 263 258 268

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Rack limit *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 7.25

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 9.7

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

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

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Supplied with torque spring not set. (3)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). (4)Stop lever setting: R2 (5)RACK LIMIT (6)Boost compensator stroke: BCL (7)Damper spring setting
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N1=300r/min R1=3.8mm N2=1100r/min Q1=3mm3/st Pr1=4+-0.05mm Pv1=2.45+-0.01V R2=(13)+0.5mm BCL=2.45+-0.1mm
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Speed control lever angle

F:Full speed
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a=18deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=79mm
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a=24deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin 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=27.5mm bb=(13)+0.5mm
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a=82deg+-5deg b=45deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the coupling to align with the pointer's groove. (4)Coupling (5)Pointer (6)Pre-stroke: aa (7)-
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aa=6.4+-0.03mm
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a=(80deg)

0000001901

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.
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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=900r/min Ra=(10.05)mm
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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=(575)r/min N3=(720)r/min N4=1100r/min RF=9.7mm Dr1=0.35mm Dr2=0+0.3mm
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