107691-3580 ZEXEL 9 400 618 975 BOSCH INJECTION-PUMP ASSEMBLY 9400618975 1076913580 220402451b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 975 9400618975

ZEXEL 107691-3580 1076913580

HINO 220402451B 220402451b

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Buy INJECTION-PUMP ASSEMBLY 107691-3580 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-3580 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0750

3. GOVERNOR 105962-0220

4. SUPPLY PUMP 105237-6480

5. AUTOM. ADVANCE MECHANIS 105681-6130

6. COUPLING PLATE 105664-2630

7. COUPLING PLATE

8. _ 159645-4220

9. _

10. NOZZLE AND HOLDER ASSY 105101-8422

11. Nozzle and Holder 23600-3222B

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE

15. NOZZLE SET 105019-2170

Include in #1:

107691-3580 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 975 9400618975

ZEXEL 107691-3580 1076913580

HINO 220402451B 220402451b

Zexel num

Bosch num

Firm num

Name

107691-3580

9 400 618 975

220402451B HINO

INJECTION-PUMP ASSEMBLY
J08C-UK K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

107691-3580

9 400 618 975

S220402451 HINO

INJECTION-PUMP ASSEMBLY
J08C-UK A K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

107691-3580

9 400 618 975

S220402451B HINO

INJECTION-PUMP ASSEMBLY
J08C-UK B K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

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

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

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

Rack position (11.8)

PWM % 54.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123.5 121.5 125.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_02

Rack position (6.8)

PWM % 26.3+-2. 8

Pump speed r/min 440 440 440

Each cylinder's injection qty mm3/st. 11 9.9 12.1

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min 1220--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 1170

Advance angle deg. 0 0 0

Remarks
Pointer stamping position

Governor adjustment_03

Pump speed r/min 1170

Advance angle deg. 0 -0.3 0

Governor adjustment_04

Pump speed r/min 1320-50

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Finish

0000001201

CU407980-224* *

Actuator advancing 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:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=1mm bb=20mm
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a=18.5deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
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aa=3deg bb=5.1+-0.03mm
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a=(20deg)

Stop lever angle

(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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0000001301

A : Stopper pin B: Connector
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0000001401

C:Shim
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0000001501

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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0000001701

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
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Information:

Loose Belt(s)
Loose fan or water pump belts will cause a reduction in air or water flow. Tighten the belts according to V-Belt Tension Chart that is shown in Specification section of this Service Manual.Bad Hose(s)
Bad hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside can become loose, and the loose particles of the hose can cause a restriction in the flow of coolant.Shunt Line Restriction
A restriction of the shunt line from the radiator top tank to the engine front cover, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and overheating.Shutters Not Opening Correctly
Check the opening temperature of the shutters. The shutters must be completely closed at a temperature below the fully open temperature of the water temperature regulators. Also, verify that fan control switches or viscous fans are operating correctly.Bad Water Temperature Regulators
A regulator that does not open, or only opens part of the way, can cause above normal heating. To test the thermostats, see the Testing and Adjusting section of this Service Manual.Bad Water Pump
A water pump with a loose impeller does not pump enough coolant for correct engine cooling. A loose impeller can be found by removing the water pump, and by pushing the shaft back and pulling it forward. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and the housing is 0.56 to 1.50 mm (.022 to .059 in).Air in Cooling System
Air can get into the cooling system in different ways. The most common causes are not filling the cooling system correctly, and combustion gas leaking into the system. Combustion gas can get into the system through inside cracks or bad cylinder head gaskets. Air in the cooling system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles hold coolant away from engine parts, preventing heat flow.Air in the cooling system can be found by the Bottle Test. The equipment needed to make this test is a one pint bottle, a bucket of water, and a hose which will fit the end of the overflow pipe of the radiator.Before testing, make sure the cooling system is filled correctly. Use a wire to hold the relief valve in the radiator cap open. Install the radiator cap and tighten it. Put the hose over the end of the overflow pipe.Start the engine and operate it at high idle rpm for a minimum of five minutes after the engine is at normal operating temperature. Use a cover on the radiator core to keep the engine at operating temperature. After five or more minutes at operating temperature, place the loose end of the hose in the bottle filled with water.