107491-3101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1074913101 220401251a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107491-3101 1074913101

HINO 220401251A 220401251a

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Cross reference number

ZEXEL 107491-3101 1074913101

HINO 220401251A 220401251a

Zexel num

Bosch num

Firm num

Name

107491-3101
107491-3102

220401251A HINO

INJECTION-PUMP ASSEMBLY
J05C-TF * 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 131425-0920

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. 17

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 12.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123.5 120.5 126.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 17 16 18

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

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(12.5)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123.5 121.5 125.5

Basic *

Fixing the lever *

Boost pressure kPa 51.3 51.3

Boost pressure mmHg 385 385

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 136.5 130.5 142.5

Fixing the lever *

Boost pressure kPa 51.3 51.3

Boost pressure mmHg 385 385

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-0.65

Boost pressure kPa 18 16.7 19.3

Boost pressure mmHg 135 125 145

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 95)

Boost pressure kPa 38 38 38

Boost pressure mmHg 285 285 285

Timer adjustment

Pump speed r/min 1170--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1120

Advance angle deg. 0 -0.3 0

Timer adjustment_03

Pump speed r/min 1250-50

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.1 5.07 5.13

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

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)Boost compensator stroke: BCL
----------
T1=AF54 BCL=0.65+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (3)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever.
----------
aa=35mm bb=0r/min cc=3.5+-0.1mm
----------
a=10.5deg+-5deg b=40deg+-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)-
----------
aa=5.1+-0.03mm
----------
a=(80deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

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 clockwise (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 counterclockwise 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)
----------
N1=1250r/min Ra=R1(12.5)+2.15mm
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Information:

TECHNICAL INFORMATION BULLETIN March 05, 2003
Articulated Truck
Cold Planer
Landfill Compactor
Excavator
Motor Grader
Off-Highway Truck/Tractor
Quarry Truck
Track-Type Tractor
Underground Articulated Truck
Wheel Loader
Wheel Tractor
Wheel Tractor-Scraper D30C (05A)
PM-565 (3TK)
PM-565B (8GS)
836 (7FR)
5110B (AAA)
24H (7KK)
69D (9SS, 9XS)
73D (1GW)
769D (BBB, 5SS, 5TR)
773D (7ER, 7CS)
771D (BCA, 6JR, 6YS)
775D (6KR, 8AS)
D10R (3KR)
D9R (ABK, ACL, 7TL, 8BL)
AD40 II (1YZ)
AD45 (BKZ)
AE40 II (BLW, 1ZZ)
988F II (2ZR)
990 II (4FR)
834B (7BR)
844 (2KZ)
631E II (1AB1446-Up, 1NB)
631E (1AB1-1445)
631G (AWK)
633E II (2PS)
637E II (1FB532-Up)
637E (1FB1-531)
637G (AXT)
651E (4YR)
657E (5YR, 6PR, 6TR, 7KR)
Component Code: 1901SUBJECT: Flashing New Software When Electronic Control Module (ECM) or Injectors Are Replaced
PROBLEM:
There have been dealer reports of engine ECMs locking up when new software is being installed. Dealer staff may see a message on the service tool such as: "The ECM is not responding to the service tool. Error code 864256". The flashing will typically hang up after 88% complete. When you reconnect, ET will not be able to communicate. Messages you typically get: "The communication adapter was unable to connect to the ATA data link. Error # 441. The requested protocol is not compatible with an existing datalink." You may also see: "The software file and the ECM are not compatible. Process aborted ? Error Code: 147456."
The two new software part numbers are:
222-XXXX (needed when a 172-0802 ECM is replaced by a 156-7156 ECM)
214-YYYY (needed when new-style injectors are installed)
SOLUTION:
If you are considering performing Product Support Program PS50424 on one of the above-listed machines, you may want to delay the program until new software is released. New software will be released in the near future to resolve this issue. Once the flashfiles are in SIS Web, a follow-up TIB will announce the new software?s availability.
On machine engines that have an older ECM that fails (145-7808 or 172-0802), the current 156-7172 production ECM will be needed for parts service. This will require using one of the 222-XXXX flashfiles. To minimize the possibility of locking-up the ECM, the dealer service staff can do one of the following:
Flash the ECM before traveling to the job site. This will require a By-Pass harness.
Flash the ECM on the engine. A By-Pass harness is recommended. If a By-Pass harness is used, disconnect the machine wiring harness before flashing the engine ECM. Dealers report that this method reduces the number of lock-ups.
If the dealer does not have a By-Pass harness, one will have to be purchased or assembled. If a new 129-2018 Wiring Harness Assembly (By-Pass) is purchased, modifications are necessary. Instructions on how to modify a By-Pass harness (Method 1: Modify a By-Pass Harness) and assemble a By-Pass harness (Method 2: Assemble a By-Pass Harness) appear later in this TIB.
Note: When flashing engine ECMs, always download the file from SIS Web to the computer?s hard drive. The service person should then upload (flash) to the ECM from the computer?s hard drive. For a listing of all models affected and the current software, refer to REHS1385-02, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors".
Method 1: Modify a By-Pass Harness
When flashing an on-engine ECM with the current files, Caterpillar recommends the use