Information injection-pump assembly
ZEXEL
106871-3200
1068713200
HINO
220002051A
220002051a
Rating:
Service parts 106871-3200 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1212
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106871-3200
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-3200
1068713200
HINO
220002051A
220002051a
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
134424-0820
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4
3.9
4
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-6 deg. 90 89.5 90.5
Cal 1-6 deg. 90 89.5 90.5
Difference between angles 3
Cyl.1-2 deg. 135 134.5 135.5
Cyl.1-2 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-7 deg. 180 179.5 180.5
Cal 1-7 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-4 deg. 270 269.5 270.5
Cal 1-4 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-3 deg. 315 314.5 315.5
Cal 1-3 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.1
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
107.2
104.2
110.2
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.2
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
111
109
113
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.7
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
126.6
123.6
129.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
6.4+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
13.7
10.7
16.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
50
50
50
Average injection quantity
mm3/st.
122
112
132
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Injection quantity adjustment_06
Adjusting point
F
Rack position
-
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
0
Fixing the lever
*
Timer adjustment
Pump speed
r/min
950+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1200
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Set idle at point G (N = N1, R = R1) and confirm that the fuel injection quantity at point F (N = N2) does not exceed Q1.
(3)Set the load lever's stop position so that R = aa (N = 0).
(4)Excess fuel setting for starting: SXL
----------
DL=5.4-0.2mm N1=300r/min R1=5.4mm N2=1000r/min Q1=0mm3/st aa=5.8+0.2mm SXL=9.7+0.2mm
----------
----------
DL=5.4-0.2mm N1=300r/min R1=5.4mm N2=1000r/min Q1=0mm3/st aa=5.8+0.2mm SXL=9.7+0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=4deg+-5deg
----------
----------
a=4deg+-5deg
0000000901
F:Full load
I:Idle
S:Stop
----------
----------
a=0deg+-5deg b=33deg+-3deg c=19deg+4deg-5deg
----------
----------
a=0deg+-5deg b=33deg+-3deg c=19deg+4deg-5deg
0000001501 MICRO SWITCH
Switch adjustment
Adjust the bolt so that the lower lever position is obtained when the switch is turned ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325-25r/min Ra=6.4mm
----------
----------
N1=325-25r/min Ra=6.4mm
----------
Information:
Parts Location
Illustration 2 g01663154
Exploded view (1) 304-1108 Diesel Particulate Filter Gp (2) 304-1111 Bracket As (3) 253-4495 Clamp As (4) 277-4718 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606033
Typical example (16) Exhaust pipe assembly (17) Clamp (18) 241-9265 Muffler Clamp (19) Pipe assembly (20) Bracket assembly (21) Support assembly (22) Muffler assembly (23) Hard washer (24) Bolt (25) Plate (26) Bolt (27) Hard washer (28) Plate (29) Washer (30) Bolt
Remove existing muffler assembly (22) and bracket assembly (20). Set aside exhaust pipe assembly (16), clamp (17), three hard washers (23), three bolts (24), three bolts (26), three hard washers (27), two washers (29), and two bolts (30). These parts will be reused in later steps.
Illustration 4 g01602298
Reuse three bolts (24) and three hard washers (23) that were used to secure the former bracket assembly (20) to secure the new 304-1111 Bracket As (2) to support assembly (21). Refer to Illustrations 3 and 4.
Reuse two bolts (30) and two washers (29) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (28). Refer to Illustrations 3 and 4.
Reuse three bolts (26) and three hard washers (27) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (25). Refer to Illustrations 3 and 4.
Illustration 5 g01602360
(3) 253-4495 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt
Install the two new 253-4495 Clamp As (3) by using four 8T-4196 Bolts (6) and four 8T-4121 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Refer to Illustration 5.
Illustration 6 g01602363
(1) 304-1108 Diesel Particulate Filter Gp (3) Clamp assembly (31) Inlet module tube
Install the new 304-1108 Diesel Particulate Filter Gp (1) on top of clamp assembly (3). Make sure that the inlet module tube (31) fits into pipe assembly (19). Use a new 241-9265 Muffler Clamp (11) to secure the joint.
Illustration 7 g01602273
(4) 277-4718 Clamp As (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut
Once you have the pipe assembly installed properly, tighten each bottom clamp assembly (3). Install the top 277-4718 Clamp As (4) by using four 5P-8245 Hard Washers (7) and four 6V-3823 Bolts (8). Use four 3B-4508 Lockwashers (9) and four 6V-8149 Nuts (10) on clamp assembly (3) side. Refer to Illustration 7.
Install exhaust pipe assembly (16) that you removed from the muffler assembly (22) to the outlet module tube of the DPF and secure the joint with existing clamp (17) that you removed from the muffler assembly.
Reconnect the drain lines.
Insulate pipe assembly (19) from the turbo end to the inlet
Illustration 2 g01663154
Exploded view (1) 304-1108 Diesel Particulate Filter Gp (2) 304-1111 Bracket As (3) 253-4495 Clamp As (4) 277-4718 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606033
Typical example (16) Exhaust pipe assembly (17) Clamp (18) 241-9265 Muffler Clamp (19) Pipe assembly (20) Bracket assembly (21) Support assembly (22) Muffler assembly (23) Hard washer (24) Bolt (25) Plate (26) Bolt (27) Hard washer (28) Plate (29) Washer (30) Bolt
Remove existing muffler assembly (22) and bracket assembly (20). Set aside exhaust pipe assembly (16), clamp (17), three hard washers (23), three bolts (24), three bolts (26), three hard washers (27), two washers (29), and two bolts (30). These parts will be reused in later steps.
Illustration 4 g01602298
Reuse three bolts (24) and three hard washers (23) that were used to secure the former bracket assembly (20) to secure the new 304-1111 Bracket As (2) to support assembly (21). Refer to Illustrations 3 and 4.
Reuse two bolts (30) and two washers (29) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (28). Refer to Illustrations 3 and 4.
Reuse three bolts (26) and three hard washers (27) that were used to secure the former bracket assembly (20) to secure the new bracket assembly (2) to plate (25). Refer to Illustrations 3 and 4.
Illustration 5 g01602360
(3) 253-4495 Clamp As (5) 8T-4121 Hard Washer (6) 8T-4196 Bolt
Install the two new 253-4495 Clamp As (3) by using four 8T-4196 Bolts (6) and four 8T-4121 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Refer to Illustration 5.
Illustration 6 g01602363
(1) 304-1108 Diesel Particulate Filter Gp (3) Clamp assembly (31) Inlet module tube
Install the new 304-1108 Diesel Particulate Filter Gp (1) on top of clamp assembly (3). Make sure that the inlet module tube (31) fits into pipe assembly (19). Use a new 241-9265 Muffler Clamp (11) to secure the joint.
Illustration 7 g01602273
(4) 277-4718 Clamp As (7) 5P-8245 Hard Washer (8) 6V-3823 Bolt (9) 3B-4508 Lockwasher (10) 6V-8149 Nut
Once you have the pipe assembly installed properly, tighten each bottom clamp assembly (3). Install the top 277-4718 Clamp As (4) by using four 5P-8245 Hard Washers (7) and four 6V-3823 Bolts (8). Use four 3B-4508 Lockwashers (9) and four 6V-8149 Nuts (10) on clamp assembly (3) side. Refer to Illustration 7.
Install exhaust pipe assembly (16) that you removed from the muffler assembly (22) to the outlet module tube of the DPF and secure the joint with existing clamp (17) that you removed from the muffler assembly.
Reconnect the drain lines.
Insulate pipe assembly (19) from the turbo end to the inlet