Information injection-pump assembly
ZEXEL
106672-3690
1066723690
HINO
220204270A
220204270a
Rating:
Service parts 106672-3690 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
8.
_
9.
_
11.
Nozzle and Holder
23600-1860D
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106672-3690
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106672-3690
1066723690
HINO
220204270A
220204270a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.3
3.2
3.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.7
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
147.5
144.5
150.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.7+-0.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
52.5
50.5
54.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
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)Idle spring not operating.
(4)RACK LIMIT
(5)Set idle sub-spring
----------
K=17
----------
----------
K=17
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=9deg+-5deg b=14deg+-5deg
----------
----------
a=9deg+-5deg b=14deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position aa or less, pump speed bb
(2)At delivery
----------
aa=6.2mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=6.2mm 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=(0deg)
----------
----------
a=(0deg)
Information:
Removal of Fuel System
To prevent dust from entering the fuel system, cover all openings in the injection pump, nozzle inlet connectors and injection pipes.
Removal of Fuel Injection Pump
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marked on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.Disassembly, Inspection and Reassembly of Fuel System
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Inspection of fuel injection nozzle valve openingCheck each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness.
Replacement of fuel injection nozzle tip 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
(2) Inspection f fuel injection nozzle spray pattern
Inspection of spray pattern of fuel injection nozzle(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.(3) Cleaning and replacement of faulty nozzles
Cleaning of fuel injection nozzle tip(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. after cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment and cleaning, replace the nozzle tip.
To prevent dust from entering the fuel system, cover all openings in the injection pump, nozzle inlet connectors and injection pipes.
Removal of Fuel Injection Pump
Removal of fuel injection pump (1)
Removal of fuel injection pump (2)(1) Check the alignment marks stamped on the flange of the fuel injection pump and the pump mounting flange.(2) Remove the front cover from the engine.(3) Place alignment marked on the fuel injection pump gear and idler gear.(4) Unscrew the mounting bolts from the fuel injection pump flange, and remove the fuel injection pump together with the flange from the front plate. (a) After the fuel injection pump is removed, do not turn the engine.(b) When removing the pump gear, loosen the gear retaining nut while the pump is mounted on the engine.Disassembly, Inspection and Reassembly of Fuel System
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Inspection of fuel injection nozzle valve openingCheck each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness.
Replacement of fuel injection nozzle tip 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
(2) Inspection f fuel injection nozzle spray pattern
Inspection of spray pattern of fuel injection nozzle(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.(3) Cleaning and replacement of faulty nozzles
Cleaning of fuel injection nozzle tip(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. after cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment and cleaning, replace the nozzle tip.