106671-8781 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066718781 220801682a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106671-8781 1066718781

HINO 220801682A 220801682a

Service parts 106671-8781 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7441

3. GOVERNOR 105489-5240

4. SUPPLY PUMP 105217-1910

5. AUTOM. ADVANCE MECHANIS 105681-5370

6. COUPLING PLATE 105663-0620

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7403

11. Nozzle and Holder 23600-2470C

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105031-7241

14. NOZZLE

15. NOZZLE SET 105019-0150

Include in #1:

106671-8781 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-8781 1066718781

HINO 220801682A 220801682a

Zexel num

Bosch num

Firm num

Name

106671-8781
106671-8782

220801682A HINO

INJECTION-PUMP ASSEMBLY
K13D * K 14CA PE6P,6PD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

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 4.6 4.54 4.6

Beginning of injection position
Drive 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 A

Rack position 7.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 140 137 143

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.4

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 147.5 145.5 149.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.6

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 155 152 158

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 3.7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.8 5.8 11.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155 175

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_06

Adjusting point H

Rack position 7.6+-0.5

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 153 147 159

Fixing the lever *

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1075-50

Advance angle deg. 4.5 4.2 4.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (N = N1) (3)Damper spring setting (4)Variable speed specification: idling adjustment (5)Fix the lever at the full-load position at delivery. (6)Main spring setting
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SXL=8.1+-0.1mm N1=350r/min
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Set the stopper bolt (fixed at full-load position at delivery.) (3)Set the pump speed at bb. (4)Set the pump speed to cc.
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aa=130mm bb=1150r/min cc=350r/min
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a=15deg+-5deg b=(12deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=45mm
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a=24deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set stopper screw so that rack position = aa (after setting, apply red paint). (2)Use the hole at R = bb (3)Drive side
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aa=(13)+-1mm bb=36mm
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a=47deg+-5deg b=33.5deg+-5deg

0000001201

(1)Variable speed specification (2)Minimum - maximum speed specification (3)Use the hole at R = aa
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aa=112mm
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a=20deg+-5deg b=(29deg)

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=900r/min Ra=(7.6)mm
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0000001601 GOVERNOR TORQUE CONTROL

Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
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N1=500r/min N2=(565)r/min N3=(700)r/min N4=850r/min RF=7.1mm Dr1=0.5mm Dr2=0+0.3mm
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0000001701 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
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L=1~2mm
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