107691-3232 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913232 220401060c

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-3232 1076913232

HINO 220401060C 220401060c

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Cross reference number

ZEXEL 107691-3232 1076913232

HINO 220401060C 220401060c

Zexel num

Bosch num

Firm num

Name

107691-3232
107691-3233

220401060C HINO

INJECTION-PUMP ASSEMBLY
J08C-TR * 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. 407910-3 03*

Selector switch no. 03

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 16

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 124 121 127

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

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.1+-0.5

Pump speed r/min 455 455 455

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

PS407910-303* V V1-0.05+ -0.01

PS407910-303* 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(12.1)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 124 122 126

Basic *

Fixing the lever *

Boost pressure kPa 64.7 64.7

Boost pressure mmHg 485 485

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.8

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 140.5 134.5 146.5

Fixing the lever *

Boost pressure kPa 64.7 64.7

Boost pressure mmHg 485 485

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position R2-1.25

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 86.5 80.5 92.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 350 350 350

Rack position R2-1.25

Boost pressure kPa 36.7 35.4 38

Boost pressure mmHg 275 265 285

Boost compensator adjustment_02

Pump speed r/min 350 350 350

Rack position R2(R1-1. 65)

Boost pressure kPa 51.3 51.3 51.3

Boost pressure mmHg 385 385 385

Timer adjustment

Pump speed r/min 0

Advance angle deg. 0 0 0

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min -

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Measure the actual speed, stop

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

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 12 11.5 12.5

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 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

Output voltage V 1.17 1.16 1.18

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.1 5.07 5.13

Output voltage V 2.8 2.6 3

Confirmation *

Remarks
Output voltage V1

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 0.95

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)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at the full setting. (4)Stop lever's normal position setting: RA (5)Boost compensator stroke: BCL
----------
T1=AE99 Ra=R1(12.1)+2.8mm RA=(18)mm BCL=1.25+-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=50mm
----------
a=8deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Speed = bb, rack position = cc (3)Use the hole above R = dd
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
a=15deg+-5deg b=35deg+-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.
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----------

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(12.1)+2.8mm
----------

Information:

ROCKER ARM SHAFT ASSEMBLY
1. Fuel return line (one each head). 2. Bolts and locks (four each head).4. Remove rocker arm shaft assembly (3). Remove push rods (4).
REMOVING ROCKER ARM SHAFT ASSEMBLY
3. Rocker arm shaft assembly (one each head). 4. Push rods (eight each head).Install Rocker Arm Shaft Assemblies
1. Lubricate the cam followers, push rods, and rocker arm shaft assembly with clean engine oil (SAE 30).2. Install push rods. Position the rocker arm shaft assembly on the cylinder head.3. Install the rocker arm shaft assembly retaining bolts and locks. Tighten bolts to 18 5 lb. ft. (2.5 0.7 mkg) and bend the locks.4. Install the fuel return line.5. Adjust the intake valve clearance to .015 in. (0.38 mm) and the exhaust valve clearance to .025 in. (0.64 mm).6. Install valve cover. Install valve cover retaining bolts and tighten bolts to 120 24 lb. in. (138 28 cm.kg).Disassemble Rocker Arm Shaft Assembly
1. Remove retaining bolts and locks from each end of rocker arm shaft assembly and disassemble the rocker arm shaft assembly.
ROCKER ARM SHAFT ASSEMBLY DISASSEMBLED
1. Rocker arm shaft. 2. Rivet. 3. Washers (eight). 4. Rocker arms (two per cylinder). 5. Adjusting screw. 6. Bracket. 7. Oil supply hole.Assemble Rocker Arm Shaft Assembly
1. The oil holes in shaft (1), arms (4) and bracket (6) must be clean and free of dirt or foreign material.2. Install adjusting screws (5) into rocker arms (4) so they extend .44 in. (11.2 mm) below arm. This will avoid forcing valves into piston crowns when rocker arm assembly is installed on cylinder head.
ROCKER ARM SHAFT ASSEMBLY
1. Rocker arm shaft. 2. Rivet. 3. Washers (eight). 4. Rocker arms (two per cylinder). 5. Adjusting screw. 6. Bracket. 7. Oil supply hole.3. Install arms (4) on shaft with washers (3) positioned as shown.4. Position shaft (1) and arms (4) into bracket (6) so screws (5) are on the same side of bracket (6) as oil supply hole (7). Rivet (2) must be on top when shaft (1) is positioned into bracket (6). Later rocker arm shaft assemblies have machined flats (8). The machined flats must be on top when shaft (1) is positioned into bracket (6).
LATER ROCKER ARM SHAFT ASSEMBLY
1. Rocker arm shaft. 6. Bracket. 8. Machined flats (four per shaft).