Rating:
Information injection-pump assembly
ZEXEL
108822-3060
1088223060
HINO
220009020A
220009020a
Cross reference number
ZEXEL
108822-3060
1088223060
HINO
220009020A
220009020a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-6-2-
7-5-4-3
Pre-stroke
mm
7.2
7.17
7.23
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
13.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
141
138
144
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.5+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
14.3
11.3
17.3
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
7.1+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
141
139
143
Basic
*
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
134
128
140
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
0000001601
Pre-stroke
mm
7.2
7.17
7.23
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.2
3.15
3.25
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
7.2
7.17
7.23
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
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 stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point B (Ra) can be obtained at full setting.]
(4)Stop lever's normal position setting: equivalent to RA
(5)Damper spring setting
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T1=AD07 Ra=R1+1mm RA=(17)mm
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T1=AD07 Ra=R1+1mm RA=(17)mm
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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=94mm
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a=17deg+-5deg b=37deg+-3deg
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aa=94mm
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a=17deg+-5deg b=37deg+-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 at rack position = cc (speed = dd).
(3)Use the hole above R = ee
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aa=(17)mm bb=0r/min cc=0.5+-0.3mm dd=0r/min ee=35mm
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a=23deg+-5deg b=35deg+-5deg
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aa=(17)mm bb=0r/min cc=0.5+-0.3mm dd=0r/min ee=35mm
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a=23deg+-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 coupling to align with the pointer's groove.
(4)Coupling
(5)Pointer
(6)Pre-stroke: aa
(7)-
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aa=7.2+-0.03mm
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a=(80deg)
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aa=7.2+-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=R1(13.3)+1mm
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N1=1100r/min Ra=R1(13.3)+1mm
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