Information injection-pump assembly
ZEXEL
101401-2361
1014012361
HINO
220205081A
220205081a
Rating:
Cross reference number
ZEXEL
101401-2361
1014012361
HINO
220205081A
220205081a
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
105780-8140
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-5720
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
1-3-4-2
Pre-stroke
mm
4.4
4.35
4.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
82.5
80.5
84.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
13.5
12
15
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
125
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-1.2
Boost pressure
kPa
8
8
8
Boost pressure
mmHg
60
60
60
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(9.6)
Boost pressure
kPa
33.3
30.6
36
Boost pressure
mmHg
250
230
270
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
0.7
0.4
1
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
2
2
2
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Main spring setting
(5)Set idle sub-spring
(6)Boost compensator stroke
----------
K=13
----------
----------
K=13
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(5deg)+-5deg b=(19deg)+-5deg
----------
----------
a=(5deg)+-5deg b=(19deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Speed = bb, rack position = cc (sealed at delivery)
(3)Stopper bolt setting
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Problem
The retainer clips for the fuel injectors may crack or break on certain Challenger 75 Tractors. Also, the unit injector rocker arms may crack.
Affected Product
Mode & Identification Number
CH75 (4CJ1-308, 4CJ311-317, 4CJ320-331, 4CJ350, 4CJ356,4CJ375-378, 4CJ380, 4CJ382, 4CJ383, 4CJ386, 4CJ391, 4CJ394, 4CJ396, 4CJ406)
Parts Needed
6 - 7E8872 Rocker Arm Assembly (Use as needed)6 - 6I2538 Clip6 - 0R3398 Injector Group (Use as needed)Action Required
See attached rework procedure.
Service Claim Allowances
If required, add the following:
0.5 Hr R&I first fuel injector0.4 Hr R&I each additional fuel injectorParts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors have recently been installed in that engine. Check SIMS history to be sure.2. Remove hood from over engine, valve covers, and rocker arm stands.3. Inspect the injector rocker arms for the heat code and die code as shown in Illustration 1. Replace any injector rocker arms that have both heat code "1" and die code "1*C" (* Note symbol in Illustration.)
Illustration 1 - Injector Rocker Arm Identification Injector rocker arms must have BOTH heat code "1" and die code "1*C" to be eligible for replacement.
4. Inspect unit injectors for a paint strip across the top face of the spring retainer (either yellow or red). A paint stripe indicates the unit injector has been reworked previously.5. Remove the return to tank fuel line at the fuel manifold adapter (siphon break) and install a 0-100 psi gauge at the manifold.6. Use an O-ring pick to remove the O-ring from the spring retainer of each injector to be reworked. Remove the rocker arm thrust pad from each injector.7. Pressurize fuel system using the priming pump to 30 psi and maintain pressure from 15-30 psi during rework (fuel pressure keeps the injector plunger extended during clip replacement).8. Inspect the 9U5300 Unit Injector Spring Compressor Group. See Illustration 2. The 9U5320 Fixture is for off engine use only.
Illustration 2 - 9U5300 Unit Injector Spring Compressor GroupInstall the compressor group into a rocker arm support bolt hole with the arm aligned over a unit injector spring. Be sure the 5P0541 Nut is backed off to the top of the 9U5321 Tube before tightening the 7X0909 Bolt.
Install the compressor at hole locations closest to the inlet valves.Tighten the 5P0541 Nut to compress the injector spring only enough to allow removal of the clip (the clip is like a valve keeper).
9. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the old clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart. See Illustration 3.
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.10. Inspect the clip
The retainer clips for the fuel injectors may crack or break on certain Challenger 75 Tractors. Also, the unit injector rocker arms may crack.
Affected Product
Mode & Identification Number
CH75 (4CJ1-308, 4CJ311-317, 4CJ320-331, 4CJ350, 4CJ356,4CJ375-378, 4CJ380, 4CJ382, 4CJ383, 4CJ386, 4CJ391, 4CJ394, 4CJ396, 4CJ406)
Parts Needed
6 - 7E8872 Rocker Arm Assembly (Use as needed)6 - 6I2538 Clip6 - 0R3398 Injector Group (Use as needed)Action Required
See attached rework procedure.
Service Claim Allowances
If required, add the following:
0.5 Hr R&I first fuel injector0.4 Hr R&I each additional fuel injectorParts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors have recently been installed in that engine. Check SIMS history to be sure.2. Remove hood from over engine, valve covers, and rocker arm stands.3. Inspect the injector rocker arms for the heat code and die code as shown in Illustration 1. Replace any injector rocker arms that have both heat code "1" and die code "1*C" (* Note symbol in Illustration.)
Illustration 1 - Injector Rocker Arm Identification Injector rocker arms must have BOTH heat code "1" and die code "1*C" to be eligible for replacement.
4. Inspect unit injectors for a paint strip across the top face of the spring retainer (either yellow or red). A paint stripe indicates the unit injector has been reworked previously.5. Remove the return to tank fuel line at the fuel manifold adapter (siphon break) and install a 0-100 psi gauge at the manifold.6. Use an O-ring pick to remove the O-ring from the spring retainer of each injector to be reworked. Remove the rocker arm thrust pad from each injector.7. Pressurize fuel system using the priming pump to 30 psi and maintain pressure from 15-30 psi during rework (fuel pressure keeps the injector plunger extended during clip replacement).8. Inspect the 9U5300 Unit Injector Spring Compressor Group. See Illustration 2. The 9U5320 Fixture is for off engine use only.
Illustration 2 - 9U5300 Unit Injector Spring Compressor GroupInstall the compressor group into a rocker arm support bolt hole with the arm aligned over a unit injector spring. Be sure the 5P0541 Nut is backed off to the top of the 9U5321 Tube before tightening the 7X0909 Bolt.
Install the compressor at hole locations closest to the inlet valves.Tighten the 5P0541 Nut to compress the injector spring only enough to allow removal of the clip (the clip is like a valve keeper).
9. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the old clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart. See Illustration 3.
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.10. Inspect the clip