108822-3052 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1088223052 220008792a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108822-3052 1088223052

HINO 220008792A 220008792a

Cross reference number

ZEXEL 108822-3052 1088223052

HINO 220008792A 220008792a

Zexel num

Bosch num

Firm num

Name

108822-3052
108822-3053

220008792A 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 105780-8250

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. 41

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 -

Rack position 15.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 181 178 184

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 8.5+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 18.1 15.1 21.1

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(15.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 181 179 183

Basic *

Fixing the lever *

Boost pressure kPa 64 64

Boost pressure mmHg 480 480

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 148.5 142.5 154.5

Fixing the lever *

Boost pressure kPa 64 64

Boost pressure mmHg 480 480

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 R2-2.4

Boost pressure kPa 22 22 24

Boost pressure mmHg 165 165 180

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 1)

Boost pressure kPa 50.7 50.7 50.7

Boost pressure mmHg 380 380 380

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 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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Set the stop lever before governor adjustment. [When setting the stop lever after governor adjustment, confirm that Ra can be obtained at the full setting.] (4)Stop lever's normal position setting: equivalent to RA (5)Boost compensator stroke: BCL (6)Damper spring setting
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T1=AD18 Ra=R1+0.3mm BCL=2.4+-0.1mm RA=18mm
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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=69mm
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a=14deg+-5deg b=(37.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = aa (speed = bb) (2)Set the stopper bolt (N = 0) (3)Use the pin above R = cc
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aa=1.5+-0.3mm bb=0r/min cc=37mm
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a=18deg+-5deg b=35deg+-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 damper to align with the pointer's groove. (4)Damper (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=900r/min Ra=R1(15.5)+0.3mm
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