Information injection-pump assembly
ZEXEL
106871-8551
1068718551
HINO
220006791A
220006791a
Rating:
Service parts 106871-8551 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2252A
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/24.5{250}
15.
NOZZLE SET
Include in #1:
106871-8551
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-8551
1068718551
HINO
220006791A
220006791a
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
134424-1020
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
4.5
4.44
4.5
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
153
151
155
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
150
147
153
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
150.4
142.4
158.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
7.95
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
122
116
128
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
F
Rack position
3.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12.1
9.1
15.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_06
Adjusting point
H
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
185
185
225
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
660
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_02
Pump speed
r/min
800--
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
880+50
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_04
Pump speed
r/min
1100-50
Advance angle
deg.
4.75
4.45
5.05
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL (N = N1)
(5)Damper spring setting
----------
RT=0.8 TH=3.5mm SXL=9.75+-0.1mm N1=300r/min
----------
----------
RT=0.8 TH=3.5mm SXL=9.75+-0.1mm N1=300r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=39mm
----------
a=39deg+-5deg b=43.5deg+-3deg
----------
aa=39mm
----------
a=39deg+-5deg b=43.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=15deg+-5deg b=64deg+-5deg
----------
----------
a=15deg+-5deg b=64deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=900r/min Ra=9.2mm
----------
----------
N1=900r/min Ra=9.2mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
preparatory steps: a) remove timing gear coverb) remove fuel injection pump housing and governorc) remove fuel transfer pump 1. Disconnect the accessory drive oil supply line (1) and the fuel drain line (2). Remove the fuel priming pump.2. Remove the accessory drive shaft gear retaining nut, washer, and sleeve. 3. Using tool (A), remove the accessory drive gear. 4. Remove four retaining bolts (3), two locks and retainer (4).5. Remove the accessory drive housing.6. Remove the accessory drive shaft and bearing as a unit from the housing. 7. Using tool (B), remove bearing (5).Install Accessory Drive Shaft
1. Heat the accessory drive shaft bearing to 300°F (149°C) and install the bearing on the shaft. 2. Install the accessory drive shaft and bearing (1) in the housing.3. Install the accessory drive housing. 4. Install the retainer, locks and retaining bolts.5. Locate top center (TC) compression stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR No. 1 PISTON in TESTING AND ADJUSTING. 6. Rotate the accessory drive shaft until tool (A) can be installed. 7. Install the accessory drive shaft sleeve, drive gear, conical washer and nut. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Tighten the retaining nut (2) to 100 10 lb. ft. (13,8 1,4 mkg).8. Connect the fuel drain line and the oil supply line. Install the fuel priming pump.concluding steps: a) install fuel transfer pumpb) install fuel injection pump housing and governorc) install timing gear cover
1. Heat the accessory drive shaft bearing to 300°F (149°C) and install the bearing on the shaft. 2. Install the accessory drive shaft and bearing (1) in the housing.3. Install the accessory drive housing. 4. Install the retainer, locks and retaining bolts.5. Locate top center (TC) compression stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR No. 1 PISTON in TESTING AND ADJUSTING. 6. Rotate the accessory drive shaft until tool (A) can be installed. 7. Install the accessory drive shaft sleeve, drive gear, conical washer and nut. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Tighten the retaining nut (2) to 100 10 lb. ft. (13,8 1,4 mkg).8. Connect the fuel drain line and the oil supply line. Install the fuel priming pump.concluding steps: a) install fuel transfer pumpb) install fuel injection pump housing and governorc) install timing gear cover