106672-3501 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066723501 220006531a


106672-3501 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 106672-3501 1066723501
HINO 220006531A 220006531a

Cross reference number

ZEXEL 106672-3501 1066723501
HINO 220006531A 220006531a


Zexel num
Bosch num
Firm num
Name
106672-3501 
106672-3509 
 
220006531A  HINO
INJECTION-PUMP ASSEMBLY
P09C-TB *

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   134424-1520
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
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   21
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   6.4 6.37 6.43
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   11
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   196 190 202
Max. variation between cylinders %   0 -5 5
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_02
Adjusting point   B
Rack position   11
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   192 190 194
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Remarks
(check)
 
Injection quantity adjustment_03
Adjusting point   D
Rack position   10.1
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   165 162 168
Max. variation between cylinders %   0 -5 5
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Injection quantity adjustment_04
Adjusting point   F
Rack position   5+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   11 8 14
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Injection quantity adjustment_05
Adjusting point   G
Rack position   8.3
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   121 119 123
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Injection quantity adjustment_06
Adjusting point   H
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   128 128
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Injection quantity adjustment_07
Adjusting point   I
Rack position   11.5+0.2
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   223 213 233
Fixing the lever   *
Rack limit   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-0.0 3
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   8.3
Boost pressure kPa   22 20 22
Boost pressure mmHg   165 150 165
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   11
Boost pressure kPa   53.3 53.3 53.3
Boost pressure mmHg   400 400 400
0000001601
Pre-stroke mm   6.4 6.37 6.43
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   5 4.5 5.5
Remarks
When the eccentric pin is tightened
 
_03
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   4 3.95 4.05
Output voltage V   2.62 2.61 2.63
Adjustment   *
_04
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   6.4 6.37 6.43
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_05
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   3.4
Output voltage V   3 2.98 3
Confirmation   *
_06
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

Test data 106672-3501
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)RACK LIMIT: RAL (3)Damper spring setting
----------
RAL=11.5+0.2mm
----------

Speed control lever angle

Test data 106672-3501
F:Full speed
----------

----------
a=12deg+-5deg

0000000901

Test data 106672-3501
F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=48mm
----------
a=25deg+-5deg b=34.5deg+-3deg

Stop lever angle

Test data 106672-3501
N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Free (at delivery) (4)Set the stopper bolt (apply red paint).
----------
aa=12mm bb=2.5-0.5mm
----------
a=40deg+-5deg b=35deg+-5deg c=(50deg)

0000001301

Test data 106672-3501
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=6.4+-0.03mm
----------
a=(40deg)

0000001901

Test data 106672-3501
(A): Pre-stroke actuator (B): Stamp housings A and B at the same time. (C): Stamping range 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.
----------

----------

0000002201 RACK SENSOR

Test data 106672-3501
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-0720) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (E) to the block (C). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
----------
L=33.5+-0.1mm N1=550r/min Ra=11mm
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