Information injection-pump assembly
ZEXEL
107691-3731
1076913731
HINO
220402541A
220402541a
Rating:
Service parts 107691-3731 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
107691-3731
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107691-3731
1076913731
HINO
220402541A
220402541a
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
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
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
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
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1220--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1170
Advance angle
deg.
0
0
0
Remarks
Pointer stamping position
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
Finish
0000001201
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=25deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=25deg+-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
----------
aa=3deg bb=5.1+-0.03mm
----------
a=(20deg)
----------
aa=3deg bb=5.1+-0.03mm
----------
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
----------
----------
----------
----------
0000001401
C:Shim
----------
----------
----------
----------
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%
----------
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
----------
Information:
1. Drain the coolant and oil from the engine.2. Remove bolt (1) and retainer (2) that hold the oil lines in the BrakeSaver control valve. 3. Disconnect oil lines (3) and (4) from the oil cooler. Remove oil lines (3) and (4) from the BrakeSaver control valve.4. Fasten a hoist to the oil cooler. 5. Remove two bolts (8) to disconnect elbow (10) from front bonnet (9). Remove two bolts (7) to disconnect front bonnet (9) from the water pump.6. Remove four bolts (5) to disconnect the rear bonnet from the cylinder block. Disconnect bracket (12).7. Remove oil cooler (11), front bonnet (9) and rear bonnet (6) from the engine as a unit. The weight is approximately 54 kg (120 lb.).8. Make a separation of front bonnet (9) and rear bonnet (6) from oil cooler (11). 9. Clean oil cooler core tubes (13) with a 3.81 mm (.150 in.) diameter rod.Install Oil Cooler (BrakeSaver)
1. Inspect all O-ring seals and gaskets for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install rear bonnet (1) and front bonnet (3) on oil cooler (2).3. Fasten a hoist, and put the oil cooler and bonnets as a unit in place on the engine. Connect bracket (4), but do not tighten the bolts at this time.4. Install the gasket and four bolts (4) that hold rear bonnet (1) to the engine block. Do not tighten the bolts at this time.5. Install the gasket and two bolts (5) that hold front bonnet (3) to the water pump. Do not tighten the bolts at this time.6. Install the gasket and bolts (6) that hold elbow (7) to the front bonnet. Tighten all the bolts. 7. Make sure the O-ring seals are in place on the oil lines, and install oil lines (8) and (9). 8. Install retainer (10) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Thread Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).9. Fill the engine with coolant and oil. See the Maintenance Guide.
1. Inspect all O-ring seals and gaskets for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install rear bonnet (1) and front bonnet (3) on oil cooler (2).3. Fasten a hoist, and put the oil cooler and bonnets as a unit in place on the engine. Connect bracket (4), but do not tighten the bolts at this time.4. Install the gasket and four bolts (4) that hold rear bonnet (1) to the engine block. Do not tighten the bolts at this time.5. Install the gasket and two bolts (5) that hold front bonnet (3) to the water pump. Do not tighten the bolts at this time.6. Install the gasket and bolts (6) that hold elbow (7) to the front bonnet. Tighten all the bolts. 7. Make sure the O-ring seals are in place on the oil lines, and install oil lines (8) and (9). 8. Install retainer (10) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Thread Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).9. Fill the engine with coolant and oil. See the Maintenance Guide.