106671-3770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066713770 220004440a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-3770 1066713770

HINO 220004440A 220004440a

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Cross reference number

ZEXEL 106671-3770 1066713770

HINO 220004440A 220004440a

Zexel num

Bosch num

Firm num

Name

106671-3770
106671-3773

220004440A HINO

INJECTION-PUMP ASSEMBLY
EK200 *

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 6-2-600

Overflow valve 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 7.6

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 145.1 142.1 148.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 142.6 140.6 144.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.8

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 148.2 145.2 151.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 13 10 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position 8.6+-0.5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 865+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1075

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)RACK LIMIT
----------
DL=3.3-0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle
----------

----------
a=21deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side viewed from upper left hand side.
----------

----------
a=40deg+-5deg b=64deg+-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=300+25r/min Ra=4mm
----------

Timing setting

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

----------
a=(0deg)

Information:

General Torque Information
Mismatched or incorrect fasteners can result in damage or malfunction, or possible injury.Take care to avoid mixing metric dimensioned fasteners and inch dimensioned fasteners.
Exceptions to these torques are given in the Service Manual, if necessary.Prior to installing any hardware, ensure that the components are in near new condition. Bolts and threads must nor be worn or damaged. Threads must not have burrs or nicks. Hardware must be free of rust and corrosion. Clean the hardware with a noncorrosive cleaner. Do not lubricate the fastener threads except with rust preventive. The rust preventive should be applied by the supplier of that component for purposes of shipping and storage. Other applications for lubricating components may also be specified in the Service Manual.For additional torque specifications, refer to SENR3130, Torque Specifications, available from your Caterpillar dealer.Standard Torque for Bolts, Nuts and Taperlock Studs
Torques for Taperlock Studs
Use these standard torque values for all fasteners unless otherwise specified in this manual or in the Service Manual.Torque for Metric Fasteners
Torque for Standard Hose Clamps-Worm Drive Band Type
The chart that follows gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose.
Torque for Constant Torque Hose Clamps
A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The constant torque hose clamp will help prevent these failures. Use a torque wrench for proper installation of the constant torque hose clamp. The constant torque hose clamp is installed correctly under the following conditions: * Screw tip (1) extends 6.35 mm (.250 in) (X) beyond the housing.* The belleville washers are collapsed nearly flat after screw (2) is tightened to a torque of 11 1 N m (98 9 lb in).