107691-3400 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913400 220401810a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-3400 1076913400

HINO 220401810A 220401810a

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Cross reference number

ZEXEL 107691-3400 1076913400

HINO 220401810A 220401810a

Zexel num

Bosch num

Firm num

Name

107691-3400
107691-3401

220401810A 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. 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 1-4-2-6- 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

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

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

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

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

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 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)Stop lever's normal position setting: STL (4)Boost compensator stroke: BCL
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T1=AG46 STL=(18)mm BCL=1.25+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=39.5mm
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a=32deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)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. (2)Pump speed aa, rack position bb (3)Use the hole above R = cc
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aa=0r/min bb=1.5+-0.1mm cc=28mm
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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)-
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aa=5.1+-0.03mm
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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
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0000001801

C:Shim
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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)
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N1=1250r/min Ra=R1(12.1)+2.8mm
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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.
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L=(6)mm N=410r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=6+-0.1mm
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Information:

1. Remove carbon seal dam (2) with pliers. Remove compression seal (1). 2. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).3. Make sure the bore in the cylinder head and the fuel inlet fittings are clean.4. Install new O-ring seals on adapter (3) and fuel injection nozzle (4).5. Install the fuel injection nozzle in the head. Turn and push the nozzle into its correct position. Never put lubricant on the nozzle or bore in the cylinder head. 6. Install the adapter in the head. Connect the nozzle and fuel injection line to the adapter. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.).7. Install the spacer and clamp (5) that hold the nozzle to the cylinder head. end by:a) install rocker shaftsDisassemble Fuel Injection Nozzles (9N3979 & 1W5829)
start by:a) remove fuel injection nozzles Do not disassemble any nozzle until test has shown it is needed. Check each nozzle with tool (A) for leakage, the pressure, at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that cannot be corrected with an adjustment or cleaning and can cause engine damage. See TESTING 9N3979 & 1W5829 FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled.
1. Remove cap (1) from the fuel injection nozzle.2. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (2) while the lift adjustment screw is held. Turn the lift adjustment screw (3) counterclockwise one turn. Hold the lift adjustment screw (3) with a 5/64" hex wrench and remove the locknut (2).
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.
3. Loosen the locknut (4) that holds the pressure adjustment screw. Use tool (D) to hold the pressure adjustment screw. 4. While the nozzle is held in one hand, tilt the nozzle and remove the pressure adjusting screw and locknut, spring, seat and valve. 5. If the valve does not slide out of the nozzle, install tool (C) and remove valve as follows: a) Push valve into nozzle with tool (C) until valve is against bottom of nozzle.b) Push down on body of tool (C) to engage collet on valve with tool (C). c) Turn nut counterclockwise and remove valve from the nozzle body. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must