Information injection-pump assembly
ZEXEL
106671-8480
1066718480
HINO
220007520A
220007520a
Rating:
Service parts 106671-8480 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2221A
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
106671-8480
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-8480
1066718480
HINO
220007520A
220007520a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
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
After startup boost setting
Timer adjustment
Pump speed
r/min
695--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
645
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
850
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_04
Pump speed
r/min
860+50
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_05
Pump speed
r/min
1075-50
Advance angle
deg.
5.5
5.2
5.8
Load
4/4
Remarks
Finish
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
----------
RT=0.8 TH=2.8mm SXL=8+-0.1mm N1=350r/min
----------
----------
RT=0.8 TH=2.8mm SXL=8+-0.1mm N1=350r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=45mm
----------
a=24deg+-5deg b=35deg+-3deg
----------
aa=45mm
----------
a=24deg+-5deg b=35deg+-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).
----------
aa=13+-1mm
----------
a=47deg+-5deg b=33.5deg+-5deg
----------
aa=13+-1mm
----------
a=47deg+-5deg b=33.5deg+-5deg
0000001501 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.
----------
N1=500r/min N2=- N3=- N4=850r/min RF=7.2mm Dr1=0.5mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=- N3=- N4=850r/min RF=7.2mm Dr1=0.5mm Dr2=0+0.3mm
----------
0000001601 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
----------
----------
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)
----------
----------
a=(3deg)
Information:
Personal injury or death can result from machine articulation or movement. Machine frames can move and a person can be crushed. Connect the steering frame lock between the front and rear frames before working on the machine.Before operating the machine, place the steering frame lock in the stored position.Failure to place the steering frame lock into the stored position before operating can result in loss of steering.
Reference: Disassembly and Assembly, M0084637, "R1700 Load Haul Dump Machine Systems"Reference: Disassembly and Assembly, M0100022, "R2900 Load Haul Dump Machine Systems"Required Parts
Table 1
Required Parts
Qty Part Number Description
1 389-9442 Insulation
1 434-1304 Insulation
1 434-1305 Insulation
7 290-1993 Cable Strap Machine Preparation
Note: Cleanliness is an important factor. Before the removal procedure, clean the exterior of the component thoroughly. Cleaning the exterior will help to prevent dirt from entering the internal mechanism.
Move the machine to a hard level surface away from operating machines and away from personnel.
Engage the parking brake. Place wheel blocks in front of the wheels and behind the wheels.
Stop the engine.
Install the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Install".
Turn the key start switch and the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery.
Release system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".Procedure
Illustration 1 g06525155
Typical example
(1) Cover As
(2) Cover As
Remove cover assembly (1) and cover assembly (2).
Illustration 2 g06525163
Typical example
(3) Hose As
Locate DEF supply hose assembly (3).
Illustration 3 g06526653
DEF supply hose on the R1700 machine
(4) 290-1993 Cable Strap
(5) 389-9442 Insulation
(6) 434-1305 Insulation
(7) 434-1304 Insulation
Illustration 4 g06526655
DEF supply hose on the R2900 machine
(4) 290-1993 Cable Strap
(5) 389-9442 Insulation
(6) 434-1305 Insulation
(7) 434-1304 Insulation
Install Item (5) through Item (7), securing with 290-1993 Cable Straps as required.Note: On the R1700 machine, 434-1305 Insulation (6) is installed over the top of 389-9442 Insulation (5).Note: On the R2900 machine, 434-1305 Insulation (6) slightly overlaps 389-9442 Insulation (5).
Install cover assembly (1) and cover assembly (2). Refer to Illustration 1.