106871-8122 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068718122 220005812a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-8122 1068718122

HINO 220005812A 220005812a

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Cross reference number

ZEXEL 106871-8122 1068718122

HINO 220005812A 220005812a

Zexel num

Bosch num

Firm num

Name

106871-8122
106871-8124

220005812A HINO

INJECTION-PUMP ASSEMBLY
F17C *

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 4.8 4.74 4.8

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 9.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 140.2 138.2 142.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136.8 130.8 142.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 138.4 135.4 141.4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 9.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 143.8 140.8 146.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position 9.4

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 119.3 116.3 122.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point F

Rack position 4.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.1 6.1 12.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Damper spring setting: DL (after setting the idle spring)
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RT=0.8 TH=2.6mm DL=5.5-0.2mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(7)deg t1=2--sec. t2=2--sec.
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N1=950+-50r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=7+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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a=14deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=50mm
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a=39deg+-5deg b=44deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=10deg+-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)
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N1=1070r/min Ra=10.1mm
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(80deg)

Information:

3. Remove nuts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rod from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners.
Never install the ring compressor on the piston unless the cylinder liner is used as a guide. Damage to the piston rings can be the result.
2. Use tool (A) and install pistons (1) and connecting rods in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.3. Install the bearing caps on the connecting rods with number on side of the bearing caps on the same side and same number as on the connecting rod.4. Install the nuts and tighten to a torque of 60 6 lb.ft. (80 8 N m). Put a mark on the nuts and caps and tighten nuts an extra 120°.5. Do Steps 1 through 4 for the remainder of the pistons.end by:a) install oil pumpb) install cylinder headDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove bearings (2) from the connecting rod and connecting rod cap.2. Remove retainer ring (1). Remove piston pin (3) from the piston and connecting rod. 3. Use tool (A) to remove the piston rings (4) from the piston. 4. Heat the connecting rod to a temperature of 350 to 500°F (177 to 260°C). Put connecting rod (6) in position on the base plate of tooling (B). Put a new bearing (5) on the adapter of tooling (B). Put the adapter in position in the connecting rod and base plate of tooling (B). 5. Install the pusher adapter (8) and pusher (7) from tooling (B) on the adapter. The old bearing is pushed out by tooling (B) as the new bearing is installed.6. Use tooling (B) to push the new bearing (5) into the connecting rod (6) until the push adapter of tooling (B) makes full contact with the connecting rod surface. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTION, Form No. SMHS7295. Use tooling (C) for later type connecting rods (tapered ends).7. Check the piston pin bore diameter after the bearing is installed. The correct dimension is 2.0012 .0003 in. (50.830 0.008 mm).8. Clean the ring grooves in the piston before rings are installed. The two compression rings have marks "UP-1" and "UP-2". The rings must be installed with these marks toward the top of the piston with "UP-1" as the top ring. After installation of all three piston rings, put piston rings in position so gaps in rings are 120° apart. 9. Use tool (A) to install the piston rings on the piston. 10. Install bearings (2) in the connecting rod and connecting rod cap. Be sure the tabs in back of bearings are in the tab