106671-8292 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066718292 220006552a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-8292 1066718292

HINO 220006552A 220006552a

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Cross reference number

ZEXEL 106671-8292 1066718292

HINO 220006552A 220006552a

Zexel num

Bosch num

Firm num

Name

106671-8292
106671-8294

220006552A HINO

INJECTION-PUMP ASSEMBLY
K13D *

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 7.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 141.4 138.4 144.4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 149.7 147.7 151.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.7

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 155.8 152.8 158.8

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. 160 160 180

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 695--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 645

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 860

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1075

Advance angle deg. 5.5 5.2 5.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting (6)Set idle at point K (N = N2, R = R1) and confirm that the injection quantity at N = N3 at point J is Q1.
----------
RT=0.8 TH=2.8mm SXL=8+-0.1mm N1=350r/min N2=325r/min R1=3.7mm N3=1000r/min Q1=0mm3/st
----------

Speed control lever angle

F:Full speed
----------

----------
a=(12deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=50mm
----------
a=16deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=15deg+-5deg b=64deg+-5deg

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)
----------
N1=900r/min Ra=7.7mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(3deg)

Information:

Mast Cab Side Bank-Lube Points and Locations
Illustration 14 g06355954
Mast cab side bank-lube points
(A) Right Mast Pivot Pin
(B) Right Mast Raise Cylinder Upper Pin
(C) Gear Box Air Seal (Top side)
(D) Gear Box Top Lip Seal Top Air Seal (Bottom Side)
(E) Pipe Rack Upper Swing Cylinder Head End
(F) Pipe Rack Carousel Support Bearing
(G) Pipe Rack Journal Bearing
(H) Pipe Rack Journal Bearing
(J) Left Side Top Sheave Pin
(K) Right Side Top Sheave Pin
(L) Left Side Bottom Sheave Pin
(M) Right Side Bottom Sheave Pin
(N) Right Side Pipe Positioner Roller Pin
(P) Right Side Pipe Positioner Swing Pin
(R) Left Side Pipe Positioner Swing Pin
(S) Left Side Pipe Positioner Roller Pin
Table 12
Mast Cab Side Bank
Item Description Sleeve color
A Right Mast Pivot Pin Red
B Right Mast Raise Cylinder Upper Pin Red
C Gear Box Air Seal (Top side) Nut
D Gear Box Top Lip Seal Top Air Seal (Bottom Side) Red
E Pipe Rack Upper Swing Cylinder Head End Red
F Pipe Rack Carousel Support Bearing Red
G Pipe Rack Journal Bearing Red
H Pipe Rack Journal Bearing Red
J Left Side Top Sheave Pin Red
K Right Side Top Sheave Pin Red
L Left Side Bottom Sheave Pin Red
M Right Side Bottom Sheave Pin Red
N Right Side Pipe Positioner Roller Pin Red
P Right Side Pipe Positioner Swing Pin Nut
R Left Side Pipe Positioner Swing Pin Nut
S Right Side Pipe Positioner Roller Pin Red Hydraulic Break Out Wrenches (Hobo)-Lube Points
Illustration 15 g06355971
Hobo-lube points
(A) HOBO Rotate Cylinder Head End
(B) HOBO Swing Pivot Pin Top
(C) HOBO Swing Pivot Pin Bottom
(D) HOBO Swing Cylinder Rod End
(E) HOBO Clamp Slide
(F) HOBO Rotate Cylinder Rod End
(G) HOBO Clamp Cylinder Rod End
(H) HOBO Clamp Pin
Table 13
Hydraulic Break Out Wrenches (HOBO)
Item Description Sleeve color
A HOBO Rotate Cylinder Head End Nut
B HOBO Swing Pivot Pin Top Red
C HOBO Swing Pivot Pin Bottom Red
D HOBO Swing Cylinder Rod End Red
E HOBO Clamp Slide Red
F HOBO Rotate Cylinder Rod End Nut
G HOBO Clamp Cylinder Rod End Nut
H HOBO Clamp Pin Red