106672-3680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066723680 220204440a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106672-3680 1066723680

HINO 220204440A 220204440a

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Cross reference number

ZEXEL 106672-3680 1066723680

HINO 220204440A 220204440a

Zexel num

Bosch num

Firm num

Name

106672-3680

220204440A HINO

INJECTION-PUMP ASSEMBLY
EP100-T * 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 134424-1420

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)
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 4.4 4.5

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 110 108 112

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 7 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 144 139 149

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Supplied with torque spring not set. (4)RACK LIMIT (5)Set idle sub-spring (6)Main spring setting
----------
K=11
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=2deg+-5deg b=13deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=4.8mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(50deg)

Information:

To ensure safety, make sure that bolts and bar for the prevention of crankshaft rotation have sufficient strength.
Flywheel
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
Installation of flywheel(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.Measurement of Flywheel Runout
Measurement of face runout and circular runoutMeasure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles. Cylinder Head and Valve Mechanisms
Installation of valve stem seal(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide. Installation of Valves and Valve Springs
Installation of valve and valve spring(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Confirmation of secure valve cotter installation(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.Installation of Cylinder Head Gasket
Installation of cylinder head gasket(1) Make sure the top surface of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of Cylinder Head
Installation of cylinder head assemblyPlace the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.Tightening of Cylinder Head Bolts
Cylinder head bolt tightening sequenceTighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.Assembly of Rocker Arm and Rocker Shaft Assembly
Assembly of rocker shaft assemblyWhen installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.Installation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
Installation of rocker shaft assembly(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal