106672-3230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066723230 220004972b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-3230 1066723230

HINO 220004972B 220004972b

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Cross reference number

ZEXEL 106672-3230 1066723230

HINO 220004972B 220004972b

Zexel num

Bosch num

Firm num

Name

106672-3230
106672-3231

220004972B HINO

INJECTION-PUMP ASSEMBLY
EP-1 K

106672-3230
106672-3231

220004972A HINO

INJECTION-PUMP ASSEMBLY
EP-1 A 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 (drive side) 134424-1420

Overflow valve opening pressure (drive side) kPa 162 147 177

Overflow valve opening pressure (drive side) kgf/cm2 1.65 1.5 1.8

Overflow valve (governor side) 134424-1720

Overflow valve opening pressure (governor side) kPa 162 147 177

Overflow valve opening pressure (governor side) 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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 4.5 4.44 4.5

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 8.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 146.7 144.7 148.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point C

Rack position 8.2

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 141.1 135.1 147.1

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_03

Adjusting point D

Rack position 7.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 131 126 136

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_04

Adjusting point E

Rack position 9.8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 180.6 177.6 183.6

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_05

Adjusting point G

Rack position 6.3

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 72.9 70.9 74.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position 4.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.4 5.4 11.4

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 6.3

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 8.4

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Set idle at delivery (3)Damper spring setting: DL (4)Rack difference between N = N1 and N = N2
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DL=3.5-0.2mm N1=1075r/min N2=700r/min
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Speed control lever angle

F:Full speed
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a=6deg+-5deg

0000000901

F:Full load I:Idle (1)Set point I (2)At delivery
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a=25deg+-5deg b=39deg+-3deg c=41.5deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Free (at delivery) (4)Stopper bolt setting
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aa=12mm bb=2.5-0.5mm
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a=40deg+-5deg b=30deg+-5deg c=(50deg)

0000001501 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
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N1=700r/min Ra=8.4mm VR=1.7+-0.01V
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0000001601 Q ADJUSTMENT PIPING

Tester fuel pipe A (B) branch piping Fuel inlet C (D) Overflow valve Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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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=(0deg)

Information:

(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Depth of bore in head for valve seat insert ... .442 .002 in.(11.23 0.05 mm)(3) Diameter of valve seat insert ... 1.9120 .0005 in.(48.565 0.013 mm) Bore in head for valve seat insert ... 1.9090 .0005 in.(44.489 0.013 mm)(4) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm)(5) Angle of the face of the valve seat insert ... 451/4° 1/2°(6) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .085 in.(2.16 mm)Minimum permissible (valve closed) ... .050 in.(1.27 mm)(7) Outside diameter of the face of the valve seat insert ... 1.735 .005 in.(44.07 0.13 mm) Maximum permissible ... 1.760 in.(44.70 mm)(8) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°Intake Valve (without valve seat insert)
(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Maximum permissible width of the face of the valve seat ... 120 in.(3.05 mm)(3) Angle of the face of the valve seat ... 301/4° 1/2°(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)Minimum permissible (valve closed) ... .036 in.(0.91 mm)(5) Outside diameter of the valve seat ... 2.045 .005 in.(52.23 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm)(6) Diameter of the bore ... 2.150 in.(54.61 mm)(7) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .170 in.(4.32 mm)Intake Valve (with valve seat insert)
TYPICAL ILLUSTRATION(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Depth of bore in head for valve seat insert ... .442 .002 in.(11.23 0.05 mm)(3) Diameter of valve seat insert ... 2.1500 .0005 in.(54.610 0.013 mm) Bore in head for valve seat insert ... 2.1470 .0005 in.(54.534 0.013 mm)(4) Maximum permissible width of the face of the valve seat insert ... .120 in.(3.05 mm)(5) Angle of the face of the valve seat insert ... 301/4° 1/2°(6) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)Minimum permissible (valve closed) ... .036 in.(0.91 mm)(7) Outside diameter of the face of the valve seat insert ... 2.045 .005 in.(52.23 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm)(8) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°