106871-8670 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068718670 220400084a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-8670 1068718670

HINO 220400084A 220400084a

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Cross reference number

ZEXEL 106871-8670 1068718670

HINO 220400084A 220400084a

Zexel num

Bosch num

Firm num

Name

106871-8670

220400084A HINO

INJECTION-PUMP ASSEMBLY
F17E * K

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

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 139 137 141

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 140 137 143

Fixing the lever *

Injection quantity adjustment_03

Adjusting point F

Rack position 3.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.7 6.7 12.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 710--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 660

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 0.7 0.4 1

Load 4/4

Timer adjustment_04

Pump speed r/min 880

Advance angle deg. 0.7 0.4 1

Load 3/4

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 5.25 4.95 5.55

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Supplied with torque spring not set. (3)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity at N = N2 at point J is Q1. (4)Excess fuel setting for starting: SXL (N = N3) (5)Damper spring setting
----------
N1=325r/min R1=3.9mm N2=1100r/min Q1=2mm3/st SXL=10+-0.1mm N3=300r/min
----------

Speed control lever angle

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

----------
a=(16deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=65mm
----------
a=10deg+-5deg b=44deg+-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 delivery)
----------
aa=12mm bb=2.5-0.5mm
----------
a=1deg+-5deg b=27.5deg+-5deg c=(34deg)

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=1100r/min Ra=9.2mm
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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:

This troubleshooting guide, when followed exactly as shown, can be an aid for the serviceman to find the cause of existing problems. The information from the measurements will also show proof if there is any basis for the complaint.Be sure to get a good description of the problem from the operator and/or the person who owns the vehicle. What they tell you about the problem can save you time and make the repair job faster and easier.Low Power And High Fuel Consumption Problems
The troubleshooting charts that follow provide a definite sequence to be followed for a logical, one by one elimination of many variables. The encircled numbers do not designate steps, but are references to detailed instructions that can not be shown on the chart. Always read the written material that corresponds with the encircled numbers on the charts.The Primary Engine Tests consist of quick and easy procedures that could identify the problem with a minimum loss of time. Always make these tests before starting the more involved troubleshooting charts.The necessary instruments to check each problem in sequence are shown on the chart. If the correct instrument is not available for the test, do not continue. The vehicle must be sent to a shop where the necessary tools are available.Whenever a problem is found and corrected, always run the test again to that point to be sure there is not a combination of problems. When the problem has been corrected and the complaint resolved, stop the test. Do not continue through the complete procedure just because it is there.When investigating possible causes, follow the letter sequence shown. Possible causes are arranged in order from more probable/easiest to check to less probable/more complex to check.Other Problems: Vehicle Or Vehicle Operation, Misfiring And Running Rough, Too Much Exhaust Smoke, Difficult Starting, Cooling System, Loss Of Coolant, Or Fuel In Crankcase Oil.
The probable causes of a problem are given in the order they most commonly take place. Check the probable causes in the same order that they are given. When troubleshooting, use the section on recommended procedures which follow each chart to check and make the necessary corrections for each probable cause.Engine Vibration Problem
The troubleshooting chart provides a definite sequence to be followed for a logical procedure to determine the frequency and amplitude of vibration so that the source of the vibration can be located and corrected.