106672-3242 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066723242 220005051a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-3242 1066723242

HINO 220005051A 220005051a

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Cross reference number

ZEXEL 106672-3242 1066723242

HINO 220005051A 220005051a

Zexel num

Bosch num

Firm num

Name

106672-3242
106672-3244

220005051A HINO

INJECTION-PUMP ASSEMBLY
K13C *

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 134424-1720

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 4.4 4.34 4.4

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 9.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 183.2 181.2 185.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point B

Rack position 9.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 191.5 188.5 194.5

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_03

Adjusting point C

Rack position 8.4

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 169.5 163.5 175.5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_04

Adjusting point E

Rack position 4.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.4 6.4 12.4

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point F

Rack position 7

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 128 126 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 7

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 9.2

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)RACK LIMIT (4)Set idle at delivery (5)Damper spring setting: DL
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RT=0.8 TH=2.4mm DL=3.8-0.2mm
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Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle (1)R = aa (2)Point E setting (3)At delivery
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aa=45mm
----------
a=25deg+-5deg b=46deg+-3deg c=48deg+-5deg

Stop lever angle

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

----------
a=40deg+-5deg b=50deg+-5deg

0000001501 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
----------
N=950r/min Ra=9.3mm VR=1.7+-0.1V
----------

Timing setting

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

----------
a=(0deg)

Information:

(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance for the pinion ... .020 to .050 in.(0.51 to 1.27 mm)2P6162 24V (Prestolite Number MES 6301 K) 3P110 24V (Prestolite Number MFY 6401 I)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5000 rpmCurrent consumption (draw) with no load: Maximum at 20 V ... 77 A(1) Tension of brush spring ... 80 to 90 oz.(2.27 to 2.55 kg)(2) Torque for housing bolts ... 8 lb. ft.(1.11 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)(4) Clearance between pinion and housing (pinion clearance) ... .020 to .050 in.(0.51 to 1.27 mm)2P2502 24V (Delco-Remy Number 1113393)
Rotation is clockwise when seen from drive end. Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20 V ... 92.5 AMaximum with solenoid at 20 V ... 120.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring* ... 36 to 40 oz.(1.01 to 1.14 kg)(2) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg) ... 80 oz.(2.27 kg)*Minimum for leaf springs 4N3182 24V (Delco-Remy Number 1114711)
Rotation is clockwise when seen from drive end.Minimum speed with no load ... 5500 rpmMaximum speed with no load ... 7500 rpmCurrent consumption (draw) at no load: Minimum with solenoid at 20V ... 108.5 AMaximum with solenoid at 20V ... 135.1 AClearance between pinion and housing (pinion clearance) ... .36 in.(9.1 mm) (1) Tension of brush spring ... 80 oz.(2.26 kg)(2) Torque for screws holding nose housing to lever housing ... 13 to 17 lb. ft.(1.8 to 2.4 mkg)(3) Torque for terminal nuts ... 20 to 25 lb. ft.(2.8 to 3.5 mkg)