108922-3010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1089223010 220008900a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 108922-3010 1089223010

HINO 220008900A 220008900a

Cross reference number

ZEXEL 108922-3010 1089223010

HINO 220008900A 220008900a

Zexel num

Bosch num

Firm num

Name

108922-3010
108922-3011

220008900A HINO

INJECTION-PUMP ASSEMBLY
V-4 * 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. 52

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-10-9-4 -3-6-5-8 -7-2

Pre-stroke mm 7.2 7.17 7.23

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-10 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-9 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-4 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-3 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-6 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-8 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-7 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 13.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 126 132

Max. variation between cylinders % 0 -4 4

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 8.5+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 18 15 21

Max. variation between cylinders % 0 -10 10

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 127 131

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 1000 1000 1000

Average injection quantity mm3/st. 127.5 121.5 133.5

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

_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 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

_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)Air cylinder OFF (6)Air cylinder ON (7)Damper spring setting
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T1=AC81 Ra=R1+1mm RA=18mm
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Speed control lever angle

F:Full speed I:Idle (1)When air cylinder ON. (2)When air cylinder OFF. (3)Stopper bolt set position 'H' (4)Use the hole at R = aa
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aa=44mm
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a=20deg+-5deg b=(12deg) c=(30deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Set the stopper bolt so that rack position = dd.
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aa=40mm bb=0r/min cc=4+-0.3mm dd=18mm
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a=10deg+-5deg b=30deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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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 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=1000r/min Ra=R1(13.4)+1mm
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0000002301 AIR CYLINDER

(A) stopper bolt (B) stopper bolt (C) stopper bolt (a) lever (b) air cylinder (c) speed lever (d) Nut (e) nut 1. Stopper bolt A adjusting method (1)When air cylinder pressure is P1, set the gap between the lever (a) and the air cylinder (b) to L1. (2)Apply P2 to the air cylinder. (3)Confirm that the speed lever (c) operates between idling and full speed positions. (4)Fix the stopper bolt A using nut d. 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P1, pump speed N1 and rack position is Ra, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Move the lever a several times and then fix the stopper bolt B using the nut e. (3)Nut d tightening torque: T1 (4)Nut e tightening torque: T2
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L1=(1)mm P1=0kPa(0kgf/cm2) P2=392+98kPa(4+1kgf/cm2) N1=820r/min Ra=8.5+0.1mm T1=4.9~7N-m(0.5~0.7kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m)
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