106871-8181 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068718181 220005863a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-8181 1068718181

HINO 220005863A 220005863a

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Cross reference number

ZEXEL 106871-8181 1068718181

HINO 220005863A 220005863a

Zexel num

Bosch num

Firm num

Name

106871-8181
106871-8183

220005863A 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

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 4.2+-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 *

Timer adjustment

Pump speed r/min 900

Advance angle deg. 1.7 1.4 2

Load 3/4

Timer adjustment_02

Pump speed r/min 1060

Advance angle deg. 4.75 4.45 5.05

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
----------
SXL=11+-0.1mm DL=4-0.2mm
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Speed control lever angle

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

----------
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=42mm
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a=39deg+-5deg b=46deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Set the stopper bolt (apply red paint). (4)Free (at shipping)
----------
aa=12mm bb=3mm
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a=(15deg) b=48deg+-5deg c=26deg+-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=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)-
----------

----------
a=(80deg)

Information:

Firing order (injection sequence) ... 1, 2, 7, 3, 4, 5, 6, 8Torque for the nuts holding the fuel injection lines ... 30 5 lb. ft.(4.1 0.7 mkg)(1) Torque for bushings ... 100 10 lb. ft.(13.8 1.4 mkg)(2) 9L8410 Spring: Length under test force ... 1.077 in.(27.36 mm)Test force ... 13.3 .7 lb.(6.03 0.32 kg)Free length after test ... 1.30 in.(33.0 mm)Outside diameter ... .774 in.(19.66 mm)(3) Bore in bearings for the rack (new) ... .4385 .0003 in.(11.138 0.008 mm) Maximum permissible bore in bearings for the rack (worn) ... .4408 in.(11.196 mm)Diameter of the fuel rack (new) ... .4360 .0002 in.(11.074 0.005 mm)Minimum permissible diameter of the fuel rack (worn) ... .4338 in.(11.019 mm)(4) Length of the pump plunger (new) ... 2.1500 .0003 in.(54.610 0.008 mm) Minimum permissible length of the pump plunger (worn) ... 2.1450 in.(54.483 mm)(5) Timing dimension for the fuel injection pumps with 8S7167 Gauge: 4.1 in. (104.14 mm) and 4.5 in. (114.3 mm) stroke engines ... 3.728 .001 in.(94.69 0.03 mm)5.0 in. (127.04 mm) stroke engine with 16° static timing ... 3.728 .001 in.(94.69 0.03 mm)5.0 in. (127.04 mm) stroke engine with 12° static timing ... 3.746 .001 in.(95.15 0.03 mm)(6) 9L9448, 9L9762 Lifter Assembly ... .867 in.(22.02 mm) 9L9449, 9L9796 Lifter Assembly ... .869 in.(22.07 mm)9L9450, 9L9797 Lifter Assembly ... .871 in.(22.12 mm)9L9451, 9L9798 Lifter Assembly ... .873 in.(22.17 mm)9L9452, 9L9799 Lifter Assembly ... .875 in.(22.22 mm)9L9453, 9L9800 Lifter Assembly ... .877 in.(22.27 mm)9L9454, 9L9801 Lifter Assembly ... .879 in.(22.32 mm)9L9455, 9L9802 Lifter Assembly ... .881 in.(22.38 mm)9L9456, 9L9803 Lifter Assembly ... .883 in.(22.43 mm)(7) Bore in front bearing for the camshaft ... 2.5640 .0005 in.(65.126 0.013 mm) Bore in center and rear bearings for the camshaft ... 1.8755 .0005 in.(47.638 0.013 mm)Diameter of front bearing surface (journal) of the camshaft ... 2.5600 .0005 in.(65.024 0.013 mm)Diameter of center and rear bearing surfaces (journals) of the camshaft ... 1.8730 .0005 in.(47.574 0.013 mm)Maximum permissible clearance between the bearings and the camshaft bearing surfaces (journals) (worn) ... .006 in.(0.15 mm)