107691-3560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913560 220402251b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-3560 1076913560

HINO 220402251B 220402251b

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Cross reference number

ZEXEL 107691-3560 1076913560

HINO 220402251B 220402251b

Zexel num

Bosch num

Firm num

Name

107691-3560
107691-3561

220402251B HINO

INJECTION-PUMP ASSEMBLY
J08C-TV * 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 11.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 115.5 112.5 118.5

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 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(11.7)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 115.5 113.5 117.5

Basic *

Fixing the lever *

Boost pressure kPa 63.3 63.3

Boost pressure mmHg 475 475

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+2.55

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 127.5 121.5 133.5

Fixing the lever *

Boost pressure kPa 63.3 63.3

Boost pressure mmHg 475 475

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 R2-1.1

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. 4)

Boost pressure kPa 50 50 50

Boost pressure mmHg 375 375 375

Timer adjustment

Pump speed r/min 1165--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1115

Advance angle deg. 0 0 0

Remarks
Pointer stamping position

Timer adjustment_03

Pump speed r/min 1115

Advance angle deg. 0 -0.3 0

Timer adjustment_04

Pump speed r/min 1275

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)Stop lever's normal position setting: R1 (4)Boost compensator stroke: BCL
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T1=AH24 R1=(18)mm BCL=1.1+-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=44mm
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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
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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
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a=(30deg)

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

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(11.7)+2.55mm N1=1250r/min V1=3+-0.01V
----------

Information:

Possible Causes/CorrectionsAir or Water in Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air cannot be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leaks at the connection between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside furl supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Water in the fuel can cause rough running and possible fuel system damage.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing And Adjusting section of the Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in). Also check for a bent or broken push rod.Bad Fuel Nozzle(s)
Find a bad nozzle by running engine at the rpm where it runs rough. Loosen the fuel line nut at the through the head adapter enough to stop fuel supply to that cylinder. Each cylinder must be checked this way. If a cylinder is found where loosening of the nut makes no difference in the rough running, test the nozzle for that cylinder. To test a nozzle, remove the nozzle from the engine and test as in Testing and Adjusting section of this Service Manual.Fuel Leakage From Fuel Injection Line Nut
Tighten nut to 40 N m (30 5 lb ft). Again check for leakage. Be sure to check fuel injection lines inside valve cover base.Bad Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting section in this Service Manual for the correct specifications and procedure to check plungers and lifters.Fuel pumps which are severely scored from debris can cause rough running but fuel dilution usually occurs before horsepower is affected.Low installation torque on the fuel pump retaining nut can cause misfire, rough running and low power.Fuel Has a High "Cloud Point"
In cold weather operation this condition should be checked first. The fuel "cloud point"