107691-3640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913640 220402271b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-3640 1076913640

HINO 220402271B 220402271b

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Cross reference number

ZEXEL 107691-3640 1076913640

HINO 220402271B 220402271b

Zexel num

Bosch num

Firm num

Name

107691-3640
107691-3641

220402271B HINO

INJECTION-PUMP ASSEMBLY
J08C-TW * K 14CG 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

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 12.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 114.5 111.5 117.5

Max. variation between cylinders % 0 -3.5 3.5

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 8.2+-0.5

Pump speed r/min 440 440 440

Each cylinder's injection qty mm3/st. 13.5 12.15 14.85

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(12.4)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 114.5 112.5 116.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

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+2.05

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 124 118 130

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-0.7

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1)

Boost pressure kPa 40 40 40

Boost pressure mmHg 300 300 300

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1(1150)

Advance angle deg. 0 0 0

Remarks
Pointer stamping position

Timer adjustment_03

Pump speed r/min N1(1150)

Advance angle deg. 0 -0.3 0

Timer adjustment_04

Pump speed r/min (1270)

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)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
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T1=AF97 Ra=R1+2.05mm RA=(18)mm BCL=0.7+-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=8.5deg+-5deg b=(37deg)+-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
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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)-
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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(12.4)+2.05mm N1=1250r/min V1=3+-0.01V
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Information:

START BY:a. disassemble governorb. remove fuel injection pumps 1. Remove rack (1) from the fuel pump housing. 2. Remove six lifters (2) from the fuel pump housing. Put identification marks on the lifters for installation purposes. 3. Remove camshaft (3) from the fuel pump housing. It may be necessary to use a soft hammer to push the camshaft out of the governor end of the fuel pump housing. 4. Remove races (4) and bearing (5) from the camshaft. Remove ring (6) if necessary. 5. Remove rack bearing (7) from both ends of the housing and dowel (8) if necessary. 6. Use tooling (A), and remove three camshaft bearings (9). 7. Remove the bolts, cover (10) and the gasket. 8. Remove pins (12), the seal and dowels (11) if necessary. Pins (12) must be pushed from the inside out.Assemble Fuel Injection Pump Housing
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. 2. Lubricate the seal with clean engine oil, and install pin (1). Pin (1) must protrude into the pump bore 2.15 .05 mm (.085 .002 in.).3. Install dowel (2) so that it protrudes into the pump bore 1.93 0.05 mm (.076 .002 in.). 4. Install the gasket, cover (3) and the bolts. 5. Install the rack bearing with tooling (A). Install the bearing until the driver comes in contact with the plate. The bearing should be installed to a depth of 83.0 0.5 mm (3.27 .02 in.) from the fuel pump mounting face. 6. Measure rack bearing (4). Dimension (X) must be 11.178 0.05 mm (.4400 .002 in.). Diameter (W) must be 12.767 0.058 mm (.5026 .0022 in.). 7. Install dowel (5). Dowel (5) must protrude 6.0 0.5 mm (.24 .02 in.) from the fuel pump housing face.8. Install the rear rack bearing with tooling (B) to a depth of 7.16 0.13 mm (.282 .005 in.) below the fuel pump housing surface. The inside diameter of the rear rack bearing must be 12.746 0.045 mm (.5018 .0017 in.). 9. Use tooling (C), and install three camshaft bearings (6). Oil holes (7) in the camshaft bearings must be positioned 30° 3° above the horizontal centerline toward the engine side of the fuel pump housing. The outer bearings must be installed 1.0 0.5 mm (0.04 0.02 in.) below the surface marked (Z). The inner bearing must be installed 218.0 0.3 mm (8.58 .012 in.) below the front surface (Y). Diameter (XX) must be 68.339 0.038 mm (2.6905 .0015 in.) after assembly. 10. Install ring (8), races (10) and bearing (9) on the camshaft. 11. Lubricate cam bearings (6) and the camshaft bearing journals with clean engine oil.12. Install camshaft (11) into the fuel pump housing.
The notch in the lifter must be in line with the dowel in the lifter bore. The lifter must slide up and down freely in