108822-3010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088223010 220008290a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108822-3010 1088223010

HINO 220008290A 220008290a

Cross reference number

ZEXEL 108822-3010 1088223010

HINO 220008290A 220008290a

Zexel num

Bosch num

Firm num

Name

108822-3010
108822-3011

220008290A HINO

INJECTION-PUMP ASSEMBLY
F20C-D * 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 131424-9620

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 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 152 150 154

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 152 149 155

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_03

Adjusting point D

Rack position 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 166.5 163.5 169.5

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point E

Rack position 4.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10.5 7.5 13.5

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

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_05

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 185 185 225

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Remarks
After startup boost setting

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Supplied with torque spring not set. (5)Stop lever setting: R1 (6)Excess fuel setting for starting: SXL (7)Set air cylinder. (8)Damper spring setting (9)Set idle at point K (N = N1, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). The prestroke at this time must be Pr1 (Pv1). ************
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RT=1 TH=2.5mm R1=(13.4)+0.2mm SXL=10.9+-0.1mm N1=300r/min R2=4.4mm N2=1100r/min Q1=3mm3/st Pr1=4+-0.05mm Pv1=2.45+-0.01V
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Speed control lever angle

F:Full speed
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a=22.5deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Set point I (at air cylinder operation)
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aa=90mm
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a=27.5deg+-3deg b=14deg+-5deg C=(1deg)

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set stopper screw so that rack position = aa (after setting, apply red paint). (2)- (3)Use the pin at R = bb
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aa=(13.4)+0.2mm bb=35mm
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a=25deg+-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 sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)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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N1=1100r/min Ra=10.4mm
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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=(570)r/min N3=(900)r/min N4=1100r/min RF=9.2mm Dr1=1.2mm Dr2=0+0.3mm
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0000002401 LEVER

1. Air cylinder adjustment (1)With the load lever in the idle position, temporarily set the distance between the load lever A and the air cylinder D at approximately L. (2)Set N1 and apply P1 to the air cylinder D. (3)Adjust set bolt (D) to obtain R1 at the same speed. (4)Lock using nut C. (5)Apply positive pressure several times. (6)Confirm that the load lever A returns to the idling position N2 at pressure P2. (7)Also at P1 confirm R1 (N1).
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L=(5)mm R1=4.4mm N1=275r/min N2=225r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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