106872-3060 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068723060 220004052a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106872-3060 1068723060

HINO 220004052A 220004052a

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Service parts 106872-3060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5660

3. GOVERNOR 105488-8920

4. SUPPLY PUMP 105237-1410

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7040

11. Nozzle and Holder 23600-1602

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105031-7140

14. NOZZLE

105015-4700

15. NOZZLE SET

Include in #1:

106872-3060 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106872-3060 1068723060

HINO 220004052A 220004052a

Zexel num

Bosch num

Firm num

Name

106872-3060

220004052A HINO

INJECTION-PUMP ASSEMBLY
EF750 * 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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 7.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 127.2 125.2 129.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 132.5 129.5 135.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 139.1 136.1 142.1

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 5.1

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point E

Rack position 7.4+-0.5

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 120 115 125

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 150 170

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position 7.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 127.9 121.9 133.9

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Beginning of damper spring operation: DL
----------
SXL=8.4+0.2mm DL=3.8-0.5mm
----------

Speed control lever angle

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

----------
a=22deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa
----------
aa=50mm
----------
a=1deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=15deg+-5deg b=64deg+-5deg

Timing setting

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

----------
a=(80deg)

Information:

Start By:a. remove radiator
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Loosen bolt (4), bolt (5), and bolt (6). Remove belts (3).2. Remove bolts (2) and fan (1). 3. Remove bolt (7) and washer (8). Put enough spacers (10) on bolt (7) to get approximately 3.18 mm (.125 in) of clearance between washer (8) and vibration damper and pulley assembly (9). Install bolt (7), washer (8), and spacers (10).
If spacers (10) are not used, damage to the bolt and/or crankshaft can result when the vibration damper and pulley are removed from the crankshaft.
4. Install tool (A) as shown, and loosen vibration damper and pulley assembly (9).5. Remove tool (A), bolt (7), washer (8), spacers (10), and vibration damper and pulley assembly (9). 6. If necessary, remove bolts (11) and vibration damper (12). The following steps are to install the crankshaft vibration damper and pulley. Inspect the vibration damper housing for leakage or dents (damage housing). If either condition exists, a replacement of the vibration damper must be made.7. Install vibration damper (12) on pulley (13). Install bolts (11).8. Install vibration damper and pulley assembly (9) and install bolt (7), spacers (10) and washer (8).
The flat side of washer (8) must be installed toward vibration damper and pulley assembly (9).
9. Tighten bolt (7) to a torque of 284 to 340 N m (210 to 250 lb ft). Hit bolt (7) with a hammer and retighten to a torque of 284 to 340 N m (210 to 250 lb ft).10. Position belts (3). Tighten bolts (4), (5), and (6). Use a belt tension gauge and make an adjustment of the belts. Measure the belt farthest from the engine. Tighten new belts until the gauge indication is 534 22 N (120 5 lb ft). Operate the engine at high idle for a minimum of 30 minutes after installing radiator and guards. Make another adjustment of the belt tension. The correct gauge indication for a used belt is 400 44 N (90 10 lb.). Tighten bolt (4), bolt (5), and bolt (6).11. Install fan (1) and bolt (2).End By:a. install radiator
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.