Information injection-pump assembly
ZEXEL
106672-3701
1066723701
HINO
220204571A
220204571a
Rating:
Service parts 106672-3701 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1870A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106672-3701
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106672-3701
1066723701
HINO
220204571A
220204571a
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
134424-1420
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
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
10.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
132.5
130.5
134.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
41.3
41.3
Boost pressure
mmHg
310
310
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11
8
14
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
R1-1.8
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
84
78
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
134
129
139
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-1.8
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(10.2)
Boost pressure
kPa
28
28
28
Boost pressure
mmHg
210
210
210
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)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Main spring setting
(6)Set idle sub-spring
----------
K=6 BCL=1.8+-0.1mm
----------
----------
K=6 BCL=1.8+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=17deg+-5deg
----------
----------
a=2deg+-5deg b=17deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=70deg+-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)
----------
----------
a=(50deg)
Information:
Fuel System Bleeding
Fuel system bleeding(1) Loosen the air vent plug on the fuel filter. (approx. 1.5 turns)(2) Move the priming button for the filter up and down.(3) When fuel flowing from the vent hole no longer contains air bubbles, tighten the vent plug.Inspection and Adjustment of No-Load Minimum (Low Idling) Speed and Maximum Speed
(a) The following adjustments were inspected and set for each engine on the test bench at the factory, and the set bolts are sealed. These settings should be checked and adjusted only at our designated service shop.(b) After the governor parts are adjusted, all external stoppers must be sealed in the same way as when adjustments were made at the factory.(c) Whether the seals are intact or not has important bearing on the validity of claims under warranty. Be sure to seal all the specified sections.(d) When inspecting or adjusting, be ready to operate the engine stop lever manually in case the engine overruns (engine operation at extremely high speed).
Prior to inspection and adjustment, conduct a warm-up operation until the coolant and oil temperatures rise above 70 °C [158 °F].(1) Starting the engine
Inspection and adjustment of no-load minimum (low idling) speed and maximum speed(a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch.(b) The engine ignites when the rotation speed reaches approximately 150 min-1, and the engine speed rises. Operate the speed control lever to maintain the engine speed between 800 and 1000 min-1.(c) After the engine speed stabilizes, return the speed control lever to the low idling position.(2) Low idling setting (no-load minimum rotation speed setting)Hold the speed control lever at the position of no-load minimum rotation speed, then secure the lever in that position using the idling adjustment screw.
If there is speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range.
(3) Governor setting (maximum rotation speed setting)(a) Keep the speed control lever at the position of the specified maximum rotation speed.(b) With the speed control lever held in that position, adjust and set the governor set bolt (maximum rotation speed set screw) to the specified rotation speed).Inspection of V-Belt Tension
(1) Press the V-belt at a midpoint between the alternator and crankshaft pulley to check the mount of belt deflection.
Inspection of V-belt tension (2) If the amount of belt deflection does not conform to the standard value, loosen the adjusting bolt and move the alternator to adjust the belt tension.Engine Break-in Operation
When the engine is overhauled, it should be mounted on a dynamometer and operated for break-in and inspection.Starting Up
(1) Before starting the engine, check the levels of coolant, engine oil and fuel, and bleed the fuel and cooling system.(2) With the fuel supply cut off, operate the starter and crank the engine for about 15 seconds to circulate engine oil.(3) Move the speed control lever slightly in the direction for increased fuel (do not move it to "full injection" position), then turn the starter switch key to the [START] position to start
Fuel system bleeding(1) Loosen the air vent plug on the fuel filter. (approx. 1.5 turns)(2) Move the priming button for the filter up and down.(3) When fuel flowing from the vent hole no longer contains air bubbles, tighten the vent plug.Inspection and Adjustment of No-Load Minimum (Low Idling) Speed and Maximum Speed
(a) The following adjustments were inspected and set for each engine on the test bench at the factory, and the set bolts are sealed. These settings should be checked and adjusted only at our designated service shop.(b) After the governor parts are adjusted, all external stoppers must be sealed in the same way as when adjustments were made at the factory.(c) Whether the seals are intact or not has important bearing on the validity of claims under warranty. Be sure to seal all the specified sections.(d) When inspecting or adjusting, be ready to operate the engine stop lever manually in case the engine overruns (engine operation at extremely high speed).
Prior to inspection and adjustment, conduct a warm-up operation until the coolant and oil temperatures rise above 70 °C [158 °F].(1) Starting the engine
Inspection and adjustment of no-load minimum (low idling) speed and maximum speed(a) Pull the speed control lever toward the HIGH SPEED side, and operate the starter switch.(b) The engine ignites when the rotation speed reaches approximately 150 min-1, and the engine speed rises. Operate the speed control lever to maintain the engine speed between 800 and 1000 min-1.(c) After the engine speed stabilizes, return the speed control lever to the low idling position.(2) Low idling setting (no-load minimum rotation speed setting)Hold the speed control lever at the position of no-load minimum rotation speed, then secure the lever in that position using the idling adjustment screw.
If there is speed range which causes dangerous torsional vibration, avoid setting the engine speed in that range.
(3) Governor setting (maximum rotation speed setting)(a) Keep the speed control lever at the position of the specified maximum rotation speed.(b) With the speed control lever held in that position, adjust and set the governor set bolt (maximum rotation speed set screw) to the specified rotation speed).Inspection of V-Belt Tension
(1) Press the V-belt at a midpoint between the alternator and crankshaft pulley to check the mount of belt deflection.
Inspection of V-belt tension (2) If the amount of belt deflection does not conform to the standard value, loosen the adjusting bolt and move the alternator to adjust the belt tension.Engine Break-in Operation
When the engine is overhauled, it should be mounted on a dynamometer and operated for break-in and inspection.Starting Up
(1) Before starting the engine, check the levels of coolant, engine oil and fuel, and bleed the fuel and cooling system.(2) With the fuel supply cut off, operate the starter and crank the engine for about 15 seconds to circulate engine oil.(3) Move the speed control lever slightly in the direction for increased fuel (do not move it to "full injection" position), then turn the starter switch key to the [START] position to start