106871-8840 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068718840 220007450a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-8840 1068718840

HINO 220007450A 220007450a

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Cross reference number

ZEXEL 106871-8840 1068718840

HINO 220007450A 220007450a

Zexel num

Bosch num

Firm num

Name

106871-8840
106871-8841

220007450A HINO

INJECTION-PUMP ASSEMBLY
F20C * 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 134424-1020

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 4.5 4.44 4.5

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. 153 151 155

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 150 147 153

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 150.4 142.4 158.4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 7.95

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 122 116 128

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.1 9.1 15.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 660

Advance angle deg. 0.3

Load 1/4

Timer adjustment_02

Pump speed r/min 800--

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_03

Pump speed r/min 880+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_04

Pump speed r/min 1100-50

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)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (N = N1) (3)Damper spring setting
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SXL=9.75+-0.1mm N1=300r/min
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Speed control lever angle

F:Full speed
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a=15deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=65mm
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a=10deg+-5deg b=43.5deg+-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=11.8mm bb=2-0.5mm
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a=(13deg) b=46.5deg+-5deg c=29deg+-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=900r/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:

start by:a) remove oil pan1. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1) from the two connecting rods. Remove the lower half of the bearings from the caps.2. Push the connecting rods away from the crankshaft and remove the upper half of the bearings.
Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod caps are removed.
Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.3. Clean the surfaces where the bearings fit. Install the upper half of the bearing in the connecting rod. Pull the connecting rod slowly on to the crankshaft.4. Install lower half of the bearing in the cap.
When the connecting rod caps are installed, make sure that the numbers on the side of the caps are next to and respective with the number on the side of the connecting rods.
Typical Example5. Check the bearing clearance with Plastigage (A). Put Plastigage (A) on the bearing.6. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts.
Do not use an impact wrench to tighten the nuts the additional 60 5°.
Do not turn the crankshaft when Plastigage (A) is in position. 7. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.8. Remove the cap. Measure the thickness of Plastigage (A). The rod bearing clearance must be 0.053 to 0.140 mm (.0021 to .0055 in.). The maximum permissible clearance is 0.15 mm (.006 in.).9. Put the caps in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more.10. Do Steps 1 through 9 again for other bearings. end by:a) install oil pan