106873-3081 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733081 220007791a


 

Information injection-pump assembly

ZEXEL 106873-3081 1068733081
HINO 220007791A 220007791a
106873-3081 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 106873-3081 1068733081
HINO 220007791A 220007791a


Zexel num
Bosch num
Firm num
Name
106873-3081 
106873-3082 
 
220007791A  HINO
INJECTION-PUMP ASSEMBLY
F20C-B * 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   4.5 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   9.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   157.6 155.6 159.6
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   9.1
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   160.7 157.7 163.7
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   9.25+-0. 5
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   143.7 139.7 147.7
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   E
Rack position   8.5
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   129 126 132
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   F
Rack position   3.9+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   12.6 9.6 15.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_06
Adjusting point   G
Rack position   9.85+-0. 1
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   178.5 174.5 182.5
Fixing the lever   *
Remarks
Startup boost setting
 
Injection quantity adjustment_07
Adjusting point   H
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   188 188 208
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   600--
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   550
Advance angle deg.   0.3
Load   1/4
Timer adjustment_03
Pump speed r/min   700--
Advance angle deg.   1 0.7 1.3
Load   4/4
Timer adjustment_04
Pump speed r/min   900+50
Advance angle deg.   1 0.7 1.3
Load   3/4
Timer adjustment_05
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

Test data 106873-3081
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 (4)Damper spring setting (5)When air cylinder is operating.
----------
N1=300r/min R1=3.9mm N2=1150r/min Q1=3mm3/st SXL=9.85+-0.1mm
----------

Speed control lever angle

Test data 106873-3081
F:Full speed
----------

----------
a=15.5deg+-5deg

0000000901

Test data 106873-3081
F:Full load I:Idle (1)When setting point K (at air cylinder operation) (2)Use the hole at R = aa (3)Stopper bolt setting
----------
aa=39mm
----------
a=39deg+-5deg b=43.5deg+-3deg c=(5deg)+-5deg

Stop lever angle

Test data 106873-3081
N:Pump normal S:Stop the pump. (1)Rack position = aa (at delivery), set before governor adjustment (2)Set the stopper bolt (apply red paint). (3)Use the pin at R = bb (4)Lever free
----------
aa=12+-0.1mm bb=37mm
----------
a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg

0000001501 LEVER

Test data 106873-3081
1. Air cylinder adjustment (1)With the load lever in the idle position, temporarily set the distance between the load lever A and the air cylinder D at approximately L. (2)Set N1 and apply P1 to the air cylinder D. (3)Adjust set bolt (D) to obtain R1 at the same speed. (4)Lock using nut C. (5)Apply positive pressure several times. (6)Confirm that the load lever A returns to the idling position N2 at pressure P2. (7)Also at P1 confirm R1 (N1).
----------
L=(5)mm R1=3.9mm N1=300r/min N2=225r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------

Timing setting

Test data 106873-3081
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Coolant
At operating temperature, the engine coolant is hot and under pressure. The cooling system and all lines to heaters or the engine contain hot liquid. When pressure is relieved rapidly, this hot liquid can turn into steam.Allow cooling system components to cool before draining. Any contact with hot liquid or steam can cause severe burns. Check the coolant level only after the engine has been stopped and the vent release valve is cool enough to remove with your bare hand.Remove the cooling system vent release valve slowly to relieve pressure. Use caution when removing vent release valve, grease fittings, pressure taps, breathers or drain plugs. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure.Cooling system additive (conditioner) contains alkali. To prevent personal injury, avoid contact with the skin and eyes and do not drink.Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.Keep all exhaust manifold and turbocharger shields in place to protect hot exhaust from oil spray in the event of a line, tube or seal failure.Batteries
Always wear protective glasses when working with batteries. Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes.Wash hands after touching batteries and connectors. Use of gloves is recommended.Do not smoke when observing the battery electrolyte levels. Batteries give off flammable fumes which can explode. Ensure there is proper ventilation for batteries which are located in an enclosure.Never disconnect any charging unit circuit or battery circuit cable from the battery when charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode.Fire or Explosion Prevention
Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury and property damage. Inspect all lines and tubes for wear or deterioration. They must be routed, supported or clamped securely. Tighten all connections to the recommended torque. Leaks can cause fires.Determine whether the engine will be operated in an environment in which combustible gases could be drawn through the air inlet system. These gases could cause the engine to overspeed, which in turn could seriously damage the engine and result in bodily injury or property damage.If your application involves the presence of combustible gases, consult your Caterpillar dealer to obtain additional information concerning protection devices suitable for the application involved.All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive.Do not smoke while refueling or in a refueling area.Do not smoke in areas where batteries are charged, or where flammable materials are stored.Always thaw a frozen battery before jump starting. Frozen batteries may explode. Batteries give off flammable fumes which can explode.Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container, in a safe place.Do not weld or flame

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Group cross 106873-3081 ZEXEL

Hino 

 
220007790A 
INJECTION-PUMP ASSEMBLY
F20C-B
106873-3081  

106873-3082 
 
220007791A 
INJECTION-PUMP ASSEMBLY
F20C-B
 
220007792A 
INJECTION-PUMP ASSEMBLY
F20C-B
 
 
INJECTION-PUMP ASSEMBLY

Hino 

 
220007792B 
INJECTION-PUMP ASSEMBLY
F20C-B
9 400 618 413 
220007792C 
INJECTION-PUMP ASSEMBLY
F20C-B
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