106971-3202 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069713202 220008882a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 106971-3202 1069713202

HINO 220008882A 220008882a

Service parts 106971-3202 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5770

3. GOVERNOR 105923-1472

4. SUPPLY PUMP 105237-4750

5. AUTOM. ADVANCE MECHANIS 105682-0100

6. COUPLING PLATE 105664-2220

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7802

11. Nozzle and Holder 23600-2750A

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

13. NOZZLE-HOLDER 105030-3591

14. NOZZLE

15. NOZZLE SET 105019-0550

Include in #1:

106971-3202 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-3202 1069713202

HINO 220008882A 220008882a

Zexel num

Bosch num

Firm num

Name

106971-3202
106971-3203

220008882A HINO

INJECTION-PUMP ASSEMBLY
V-3 * K

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 134424-4120

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

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-10-9-4 -3-6-5-8 -7-2

Pre-stroke mm 4.2 4.14 4.2

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-10 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-9 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-4 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-3 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-6 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-8 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-7 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 12.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 132.5 129.5 135.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 455 455 455

Average injection quantity mm3/st. 15 12 18

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 132.5 130.5 134.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 118 112 124

Fixing the lever *

Timer adjustment

Pump speed r/min 720--

Advance angle deg. 0 0 0

Load 2/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 670

Advance angle deg. 0.3

Load 2/5

Timer adjustment_03

Pump speed r/min (790--)

Advance angle deg. 2 1.7 2.3

Load 5/5

Timer adjustment_04

Pump speed r/min 880

Load 2/5

Remarks
Measure the actual advance angle.

Timer adjustment_05

Pump speed r/min 890

Advance angle deg. 2 1.7 2.3

Load 4/5

Timer adjustment_06

Pump speed r/min (960--)

Advance angle deg. 2 1.7 2.3

Load 5/5

Timer adjustment_07

Pump speed r/min 1080-50

Advance angle deg. 6.75 6.45 7.05

Load 5/5

Remarks
Finish

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)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point I (Ra) can be obtained at full setting.] (4)Stop lever's normal position setting: equivalent to RA (5)Air cylinder OFF (6)Air cylinder ON (7)Damper spring setting
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T1=AD25 Ra=(R1+0.7)mm RA=18mm
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Speed control lever angle

F:Full speed I:Idle (1)When air cylinder ON. (2)When air cylinder OFF. (3)Stopper bolt set position 'H' (4)Use the hole at R = aa
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aa=47mm
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a=20deg+-5deg b=(12deg) c=(30.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Set the stopper bolt so that rack position = dd.
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aa=40mm bb=0r/min cc=4+-0.3mm dd=18mm
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a=8.5deg+-5deg b=30deg+-5deg

0000001501 AIR CYLINDER

(A) stopper bolt (B) stopper bolt (a) lever (b) air cylinder (c) speed lever (d) Nut (e) nut 1. Stopper bolt A adjusting method (1)When the air cylinder pressure is P1, confirm that there is a clearance between the stopper bolt (A) and the lever (a). (2)Then, screw in the stopper bolt A until it contacts the lever a. (3)Further screw in L1 and set temporarily. (4)Apply P2 to the air cylinder. (5)Confirm that the speed lever (c) operates between idling and full speed positions. (6)Fix the stopper bolt A using nut d. 2. Stopper bolt <B> adjustment method. (1)At air cylinder pressure P1, pump speed N1 and rack position is Ra, adjust stopper bolt (B) so that the speed lever (c) is in the stop position. (2)Move the lever a several times and then fix the stopper bolt B using the nut e. (3)Nut d tightening torque: T1 (4)Nut e tightening torque: T2
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P1=0kPa(0kgf/cm2) L1=0.5mm P2=686+98kPa(7+1kgf/cm2) N1=820r/min Ra=8+-0.1mm T1=4.9~7N-m(0.5~0.7kgf-m) T2=4.9~7N-m(0.5~0.7kgf-m)
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