106672-3514 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066723514 220006723a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-3514 1066723514

HINO 220006723A 220006723a

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Service parts 106672-3514 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5963

3. GOVERNOR 105489-2263

4. SUPPLY PUMP 105237-1960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0820

7. COUPLING PLATE

8. _ 159590-5920

9. _

10. NOZZLE AND HOLDER ASSY 105101-7102

11. Nozzle and Holder 23600-2221A

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

13. NOZZLE-HOLDER 105031-7241

14. NOZZLE

15. NOZZLE SET 105019-0030

Include in #1:

106672-3514 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106672-3514 1066723514

HINO 220006723A 220006723a

Zexel num

Bosch num

Firm num

Name

106672-3514
106672-3515

220006723A HINO

INJECTION-PUMP ASSEMBLY
K13D * K 14CJ TICS HD-TI6M TICS

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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 21

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 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 8.6

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 137.4 134.4 140.4

Fixing the lever *

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 9.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148.8 146.8 150.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_03

Adjusting point D

Rack position 9.5

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 160.2 157.2 163.2

Fixing the lever *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_04

Adjusting point -

Rack position 5.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.8 8.8 14.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point F

Rack position R1(10.1) +-0.1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 184.5 181.5 187.5

Fixing the lever *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Startup boost setting

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

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (3)Excess fuel setting for starting: SXL (N = N3) (4)Damper spring setting
----------
N1=325r/min R1=4.9mm N2=1000r/min Q1=4mm3/st SXL=(10.1)+-0.1mm N3=300r/min
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Speed control lever angle

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

----------
a=18deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=28.5deg+-3deg

Stop lever angle

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

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

0000001301

(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=(0deg)

0000001901

(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.
----------

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0000002201 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=1000r/min Ra=(9.5)mm
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Information:

(a) When regrinding journals of the crankshaft, be sure to refinish all journals to the same dimension.(b) Finish the fillet radius to R3 0.2 mm [0.1181 0.0079 in.].
Inspection of Oil Seal Contact Surface
Check the oil seal contact surface of the crankshaft back-end, and, if the crankshaft face has been excessively worn by the oil seal, replace the oil seal and oil sleeve with replacement parts.
Inspection of oil seal contact surface(1) Installation of oil seal sleeveTo install the oil seal sleeve, coat the inner surface of the sleeve with oil, and use the crankshaft sleeve installer for driving the sleeve into place.
Be careful not to dent or scratch the outer surface of the oil seal sleeve.
When the oil seal slinger becomes worn after engine operation, remove the oil seal sleeve by following the procedure below, and replace it with a replacement oil seal assembly (oil seal and oil seal sleeve).
Inspection of oil seal sleeve
Inspection of oil seal contact surface(2) Removal of oil seal sleeveAt three locations on the sleeve end face, hold a chisel at a right angle to the sleeve and strike with a hammer, and remove the sleeve when it becomes loose.If this method does not allow the removal of the sleeve, hold the chisel in the axial direction and lightly tap to expand and loosen the sleeve.
Be careful not to damage the crankshaft with the chisel when removing the oil seal sleeve.
Removal of oil seal sleeveMeasurement of Crankshaft Runout
Support the crankshaft on its front and rear journals in V-blocks, and measure the runout at the center journal with a dial gage. Compare the amount of runout with the standard. If the runout is small, correct by grinding. If the runout is large, straighten with a press.If the runout exceeds the limit significantly, replace the crankshaft.
Measurement of crankshaft runoutRemoval of Crankshaft Gear
Use the gear puller to remove the crankshaft gear. Do not remove the crankshaft gear unless the crankshaft or gear is replaced.
Removal of crankshaft gearInstallation of Crankshaft Gear
(1) Heat the gear to a temperature of 100 to 150 °C [212 to 302 °F].(2) Install the key to the crankshaft.(3) Align the gear with key and insert the gear fully.
Installation of crankshaft gearMeasurement of Cylinder Bore
(1) Using a cylinder gage, measure the cylinder bore and cylindricity. If the limit value is exceeded even at one place, bore all cylinders and replace the pistons and piston rings with oversize pistons and piston rings. Measure at three locations each in directions A and B shown in the diagram.
Measurement of inside diameter of cylinder(2) Boring of cylinders(a) Since there are two piston oversizes (0.25 mm [0.0098 in.] and 0.50 mm [0.0197 in.] oversize) as indicated above, determine the appropriate piston size to be used based on the largest cylinder bore diameter.(b) Measure the outside diameter of the piston to be used. The piston diameter measuring points are shown in the diagram.(c) Based on the measurements of the piston outside diameter, calculate the finishing dimension to be achieved by