INJECTION PUMP CALIBRATION DATA

1/6

Ass'y No.: 107691-3570

C ON F I D EN T I AL

ENGINE MODEL: J08C-UJ

Date:
29 Nov 2002
Company: HINO
No.
22040-2341B
Pre-stroke actuator:
159645-4120

Governor: EP/RLD-J
105933-1700

Injection pump: TC6MD

107069-0740

1. Test conditions

Pump rotation: Counter clockwise ( viewed from drive side )

Nozzle & Nozzle Holder Ass'y: 105780-8250

(Bosch Type No. 1 688 901 101)

Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

Nozzle Holder: 105780-2190

(Bosch Type No.

Nozzle opening pressure: 20.7 MPa { 211 kgf/cm2 }

Transfer pump pressure: 255 kPa { 2.6 kgf/cm2 }

Length 600 mm

Injection pipe: Outer Dia. 8 mm Inner Dia. 3 mm

+5

Test Oil: ISO4113 or SAE Standard Test Oil { SAE J967d }

Oil Temp. 40 C

Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 }

DIGI switch No.: 17 (For C/U 407980-224*)

2. Injection timing
Pre-stroke: No. 1 Plunger 5.1 0.03 mm
Connector 1

Note:
1. Adjust using the shim 3.
2. Adjust with the rack in the full-load position.
3. Adjust with the connector 1 contacting the stopper 2.

Injection order: 1

4,1

60 15'

2,1

120 15'

6,1

180 15'

Stopper 2
(Timing retard side)

Shim 3

3,1

240 15'

300 15'

Plungers are numbered from the Governor side.

Tappet clearance: Manually rotate the camshaft 2 ~ 3 times and confirm that it rotates smoothly.

3. Pre-stroke actuator adjustment

Pre-stroke actuator type: Retard
Power supply voltage:

240.5 V

Pre-stroke
(mm)

Pre-stroke sensor
output voltage (V)

2.0 0.05

2.83 0.01

5.1 0.03

V1 = 1.2 0.2

Above 3.05

Ambient temperature: 235C

Remarks
Pre-stroke actuator adjustment
Confirmation
Confirmation
(Pre-stroke actuator operating range)

Bosch Automotive Systems Corporation

Service Department

3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan

Tel. (048)470-1559, Fax. (048)474-9856

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Note:
1. Move the pre-stroke actuator fully clockwise (viewed from the drive side), and temporarily secure it to the actuator
housing using the bolts.
Tightening torque: 1.0 ~ 1.5 Nm {0.1 ~ 0.15 kgfm}
2. Move the pre-stroke actuator counter clockwise (viewed from the drive side) to adjust it.
3. After pre-stroke actuator adjustment, stamp both the pre-stroke actuator and the housing with an aligning mark.

Stamping position
Pre-stroke actuator

Injection pump

4. Injection quantity variation rate adjustment

P = pre-stroke sensor output at injection quantity adjustment
P1

V = 2.25 0.01 (V)

3.1 0.05 (mm)

P2

V =V1 + 0.050.01 (V)

5.0 0.03 (mm)

Adjusting
P
point

Rack
position
(mm)

Pump
speed
(r/min)

12.7

750

P1

P2 8.20.5

440

Injection q'ty
(cm / 1000 strokes )
3

114.5 3
Each cylinder 13.51.35

Max. variation
between
cylinders (%)

Fixed

Remarks

3.5

Rack

Basic

Rack

Adjust injection q'ty at N = 440.

Adjust governor as per gov. adj. spec.

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5. Governor adjustment
Full load adjustment
Torque cam no. AH02
Stop lever normal position setting: (18.0)

Rack position (mm)

Boost compensator stroke: 1.150.1

R1+2.05
R1+1.1
Approx R1+0.25
R1(12.7)
12.30.1
R1-0.25
R2[R1-1.0]

B
I

9.31.0

Below 225 650 (700) (950) (1050)

(500)

(800)

(1300) 1510 1575

(1200)

(1470)

Pump speed (r/min)

Boost compensator adjustment

Rack position (mm)

Idling adjustment

10.0
+0.2

Rack position (mm)

9.7 -0.3

N = 300

R2[R1-1.0]

R2-1.15
0

Approx 8.2
8.0

36.01.3 {27010}

6.70.1

Boost pressure kPa {mmHg}

5.10.6

Approx 48.7 {Approx 365}

190

350 400
275
Pump speed (r/min)

700

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6. Injection quantity adjustment (after governor adjustment)
P = pre-stroke sensor output at injection quantity adjustment
P1

V = 2.25 0.01 (V)

3.1 0.05 (mm)

P2

Rack
position
(mm)

Adjusting
P
point

Pump
speed
(r/min)

Injection q'ty
(cm / 1000 strokes )
3

Max. variation
between
cylinders (%)

Fixed

P1 R1(12.7)

750

114.5 2

Lever

P1 R1+2.05

1250

124 6

Lever

Remarks

Basic

Boost press. kPa {mmHg}

Above 62.0 {Above 465}
Boost press. kPa {mmHg}
Above 62.0 {Above 465}

7. Control lever angle

Speed-control lever angle

Stop lever angle

)
(38
Full-speed

8.5

Stop

Normal

Idling

Stopper bolt setting

15 5

N=0, R=1.50.1

35 5

R=(18.0)
Stopper bolt setting

Note;
After adjusting the governor, confirm that the rack position is
at R1(12.7)+2.05 (B) with full set when setting the stop lever.

8. Timing advance specification

Pump speed
(r/min)

Below 1200

1150

1290

Advance
angle ( )

Start
0

0-0.3

Finish
-1.50.3

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9. Injection timing setting
Pointer
Injection timing aligning mark

At No. 1 plungers beginning

of injection position
(Pre-stroke: 5.10.03 mm)

Approx
Flywheel

.30 Coupling key groove position

(Actual shapes and positions may differ

from the illustration.)

1. Turn the pre-stroke actuator OFF.

2. Position the camshaft in the No.1 plunger's beginning of injection position.
3. Confirm that the injection pump pointer's aligning mark and the flywheel's aligning mark are aligned.
4. If not aligned, remove the incorrect flywheel aligning mark and remark it.
5. Confirm that the center of the flywheel's threaded hole is as specified.

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10. Rack sensor adjustment
Amp-equipped rack sensor adjustment (154610-5*20)
Threaded type rack sensor (without rack limit; for P type, TICS)
Rack sensor power supply

50.01V

Speed No

1250 r/min

Rack position Ro

R1(12.7) + 2.05 mm

Output voltage VR

3.000.01V

(1) Screw in bobbin 1 until it contacts the joint 2.

(2) Fix the pump lever at full and screw in the bobbin 1 to adjust the depth so that the amps output
voltage V = VR at Np = No and R = Ro. Then, fix the rack sensor using the nut 6.
(3) Move the pump lever 2 or 3 times, reset at full and confirm that the amps output voltage V = VR.
(4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 - nut 6 join, and the
pump end face - joint 2 join.
Note:
(1) When adjusting the bobbin 1 and joint 2, the fully tightened position of the bobbin is 9 threads (ie, 9
turns) from where it first engages the joint.
(2) With the welded rack block type, refer to the table below for the R = Ro range (the range varies with
the joint).
Rack sensor adjusting position

Rack position

Adjustment Np = No
Output voltage

Ro

VR

No

Ro

Np

Joint part no.

Ro

154614-2500

10.2 ~ 13.7

154614-4800

5.2 ~ 8.7

154614-8300

15.2 ~ 18.7

154614-8400

20.2 ~ 23.7

154614-8700

7.7 ~ 11.2

154614-8800

12.7 ~ 16.2

154614-8900

17.7 ~ 21.2

Pump end face

Pump end face

1 2

Apply red paint

Threaded rack block type

1 2

Welded rack block type

Apply red paint