Information injection-pump assembly
ZEXEL
107691-3244
1076913244
HINO
220401210E
220401210e
Rating:
Service parts 107691-3244 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
23600-3210C
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-3244
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107691-3244
1076913244
HINO
220401210E
220401210e
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.6
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
101
98
104
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
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
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(10.6)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
101
99
103
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
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
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
108.5
102.5
114.5
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Boost compensator adjustment
Pump speed
r/min
350
350
350
Rack position
R2-0.25
Boost pressure
kPa
42.7
41.4
44
Boost pressure
mmHg
320
310
330
Boost compensator adjustment_02
Pump speed
r/min
350
350
350
Rack position
R2(R1-1.
35)
Boost pressure
kPa
48
48
48
Boost pressure
mmHg
360
360
360
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).
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
Measure the actual speed, stop
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
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)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=AF00 Ra=R1+2mm RA=(18)mm BCL=0.25+-0.1mm
----------
----------
T1=AF00 Ra=R1+2mm RA=(18)mm BCL=0.25+-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=39.5mm
----------
a=32deg+-5deg b=37deg+-3deg
----------
aa=39.5mm
----------
a=32deg+-5deg b=37deg+-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=28mm bb=0r/min cc=1.5+-0.1mm
----------
a=15deg+-5deg b=40deg+-5deg
----------
aa=28mm bb=0r/min cc=1.5+-0.1mm
----------
a=15deg+-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)
----------
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(10.6)+2mm
----------
----------
N1=1250r/min Ra=R1(10.6)+2mm
----------
0000002301 AIR CYLINDER
1. Air cylinder adjustment procedure
(1)Set the speed lever at idle.
(2)Temporarily set the clearance between the air cylinder (C) and the set bolt (B) to L1.
(3)Set the speed at N.
(4)Apply positive pressure P1 to the air cylinder (C).
(5)Gradually push out the set bolt (B).
(6)Tighten the nut (D) at the point where the rack position is Ra at speed N.
(7)Apply positive pressure P1 several times.
(8)Confirm that the lever returns to the idle position at positive pressure P2.
----------
L=(6)mm N=410r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=6+-0.1mm
----------
----------
L=(6)mm N=410r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=6+-0.1mm
----------
Information:
REMOVING CAM FOLLOWERS WITH MAGNET2. Remove the plug from the timing pin hole in the fuel injection pump housing and install timing pin (2).
TIMING PIN INSTALLED
1. FT887 Timing Pin (Fabricated Tool).3. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the slot in the fuel injection pump camshaft.
PUMP DRIVE GEAR
2. Bolts (three). 3. Tachometer drive assembly. 4. Drive gear.4. Remove bolts (2) and tachometer drive assembly (3) from the fuel injection pump camshaft.5. Remove the fuel injection pump drive gear (4) from the fuel injection pump camshaft.6. Remove the camshaft thrust pin (5) from the rear of the cylinder block.
REMOVING THRUST PIN
5. Thrust pin.7. Pull the camshaft (6) out of the cylinder block, being careful to not damage the camshaft bearings or journals.
REMOVING CAMSHAFT
6. Camshaft.Install Camshaft
1. Lubricate the camshaft bearing surfaces with clean engine oil (SAE 30).2. Install the camshaft aligning timing mark on camshaft gear with timing mark on crankshaft gear.3. Install camshaft thrust pin (5) in rear of cylinder block. Tighten thrust pin to 35 5 lb. ft. (4.8 0.7 mkg).
TIMING MARKS4. Put timing plate (7) on the engine and thread bolt (8) into the timing gear. If bolt (8) will not thread into the timing gear, rotate the crankshaft CLOCKWISE (as viewed from front of engine) until bolt (8) threads into the timing gear.
TIMING PLATE INSTALLED
4. Gear. 7. 5P950 Timing Plate. 8. Bolt.
GEAR INSTALLED
4. Drive gear.5. Install drive gear (4) on the fuel injection pump camshaft with the holes in the position shown and the part number facing out. To be able to advance the timing adjustment without removing the front cover, position gear (4) in the direction of the arrow so the bolt holes in the fuel injection pump camshaft are off center as shown. The bolts must thread freely into the holes in the fuel injection pump camshaft.6. Install the tachometer drive assembly (3) and tighten it finger tight.7. Install bolts (2) and tighten the bolts to 32 5 lb. ft. (4.4 0.7 mkg). Tighten the tachometer drive assembly to 50 10 lb. ft. (6.9 1.4 mkg).8. Remove bolt (8) and remove the timing plate (7) from the engine.
TACHOMETER DRIVE ASSEMBLY INSTALLED
2. Bolts (three). 3. Tachometer drive assembly. 4. Pump drive gear.9. Remove timing pin (1) from fuel injection pump housing and install the plug in the timing pin hole.10. Install the cam followers in the same location from which they were removed. Always use the new cam followers with a new camshaft. Be sure to put engine oil on the cam followers and camshaft lobes before installing the cam followers.