Information injection-pump assembly
ZEXEL
106671-8271
1066718271
HINO
220203530A
220203530a
Rating:
Cross reference number
ZEXEL
106671-8271
1066718271
HINO
220203530A
220203530a
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
9.2
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
118.5
116.5
120.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
4.6+-0.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
10
7
13
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
950
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
4.5
4.5
4.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Idle sub spring setting: L1.
----------
K=14 L1=5.3-0.5mm
----------
----------
K=14 L1=5.3-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=16deg+-5deg
----------
----------
a=4deg+-5deg b=16deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At shipping
----------
----------
a=38deg+-5deg b=53deg+-5deg
----------
----------
a=38deg+-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:
Illustration 7 g06347860
Injector male spade terminals
There are two options to build injector adapter harness for C3.3.If available, use the injector connector removed from C3.3 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.
Illustration 8 g06345429
Injector adapter harness C2.4
Illustration 9 g06346223
Injector adapter harness C3.8
Illustration 10 g06346237
Injector male spade terminals
There are two options to build injector adapter harness for C2.4.If available, use the injector connector removed from C2.4 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.Injector Test Set-up
Illustration 11 g06346391
Mounted nozzle test group
Find a suitable stable and surface to either mount or place the nozzle test group. Fill fuel container with #1 diesel and install high-pressure hose assembly. Use adaptors, if needed, based on nozzle tester. Tighten the fuel line adapter to (25 ft lbs). Install the fuel line adapter and tighten to (25 ft lbs) to allow connection to the injector.
Illustration 12 g06346423
Injector holder assembly
Take the injector test kit and remove all parts to assemble, as shown above. Take the injector holder and the clear fuel shield with screws from the kit and remove the screws using a 3mm alan wrench. Assemble the parts so the clear fuel shield with screws is on the bottom. While, the mounted injector holder is on top with the screws removed from before.
Illustration 13 g06346719
Fuel collector and injector holder
Place injector holder onto a fuel collector or another container to capture the injection spray.
Illustration 14 g06346839
Injector setup and harness connection
Install the injector that is needing to be tested into the opening at the top of injector holder. Attach the return fuel drain hose and run the drain hose to another fuel collector. Make the harness connection using the correct adapter for the C2.4, C3.3, and C3.8 engines. Connect the injector pulse tool and the injector adapter harness to the injector.
Illustration 15 g06346868
Complete setup of nozzle tester and injector test kit
Once injector test kit and nozzle test group are set up, connect fuel line adaptor on the high-pressure hose assembly to the injector, leave connection loose. Actuate the lever on the nozzle test group until fuel drips from connection allowing air to purge from setup. Tighten fuel line adaptor at injector to (25 ft lbs).Injector Test Procedure
Illustration 16 g06346881
Mounted nozzle test group (close-up)
Inspect the injector for any leaks. Using the lever on the nozzle tester group, build injection fuel pressure to (5000 psi). Turn the locking valve to insure there is no leakage back through the tester.
Let the nozzle test