Information injection-pump assembly
ZEXEL
106873-3051
1068733051
HINO
220801571A
220801571a

Rating:
Service parts 106873-3051 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2430B
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
106873-3051
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106873-3051
1068733051
HINO
220801571A
220801571a
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
4.8
4.74
4.8
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
8.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
139.3
137.3
141.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.95+-0.
5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
133.1
127.1
139.1
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
E
Rack position
3.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
10.4
7.4
13.4
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
F
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
139
139
Max. variation between cylinders
%
0
-15
15
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
820--
Advance angle
deg.
0.7
0.4
1
Load
4/4
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
0.7
0.4
1
Load
3/4
Timer adjustment_05
Pump speed
r/min
1100-50
Advance angle
deg.
5.25
4.95
5.55
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
(5)Damper spring setting
(6)Variable speed specification: idling adjustment
(7)Main spring setting
(8)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
----------
RT=0.8 TH=2.7mm SXL=10.25+-0.1mm N1=325r/min R1=3.8mm N2=1100r/min Q1=3mm3/st
----------
----------
RT=0.8 TH=2.7mm SXL=10.25+-0.1mm N1=325r/min R1=3.8mm N2=1100r/min Q1=3mm3/st
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=21deg+-5deg b=19deg+-5deg
----------
----------
a=21deg+-5deg b=19deg+-5deg
0000000901

F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=42mm
----------
a=39deg+-5deg b=43.5deg+-3deg
----------
aa=42mm
----------
a=39deg+-5deg b=43.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Rack position = aa (at delivery), set before governor adjustment
(2)Set the stopper bolt (apply red paint).
(3)Use the pin at R = bb
(4)Lever free
----------
aa=12+-0.1mm bb=37mm
----------
a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg
----------
aa=12+-0.1mm bb=37mm
----------
a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg
0000001501 LEVER

2-stage changeover lever adjustment
(A) Speed lever
(B) Load lever
(C) 2-stage changeover lever
(D) Link
(E) Bolt
(G) Variable speed specifications
(H) Minimum maximum speed specifications
F:Full speed
I:Idle
1. Minimum-maximum speed specification adjustment (when running)
(1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper.
(2)In this condition, the load lever is held in the idle position.
(3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L.
(4)Lock using the nut.
2. Variable speed specification adjustment (at operation)
(1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.)
(2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------
----------
L=1~2mm
----------
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:
Lubricant Information
Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. SPC is a Caterpillar designation for special synthetic oils, that do not contain viscosity improvers. The MIL specifications are U.S.A. Military Specifications. The definitions other than Caterpillar's will be of assistance in purchasing lubricants. The recommended oil viscosities can be found in the"Lubricant Viscosities" chart in this publication.The grease is classified by the National Lubricating Grease Institute (NLGI) based on the ASTM D217-68 Worked Penetration characteristics which are given a defined consistency number.Engine Lubricant Specification
Caterpillar has an oil formulation to provide maximum performance and life in your truck engine.Engine Oil (EO)
Cat Engine Oil (EO) is a lubricant that meets the performance requirements of today's newer truck engines as well as meeting the needs of earlier built truck engines. This oil has sufficient TBN and sulfated ash level to be effective in operation.* Cat Engine Oil (EO)This lubricating oil also meets the industry standards for both diesel and gasoline engine requirements.Cat Engine Oil is Caterpillar's recommendation for an engine oil specifically intended for use in mixed fleets. This oil is only for the convenience of having the same oil for gasoline and diesel engines.Alternate Oils
Failure to follow these recommendations for CE performance oils can cause shortened engine life due to carbon deposits or excessive wear.
If an oil other than Cat oil is to be used, the following oil specifications provide selection guidelines.If circumstances require the use of an oil other than the Cat Engine Oil, the following oil specifications can be used; API specification CE, CE/SF or CE/SG.Oil with these specifications may require shortened oil change periods as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The Caterpillar 20 times rule for TBN versus fuel sulfur is a general requirement, but it can be modified by used oil analysis. The effectiveness of an oil formulation will depend on the additive package. A balanced additive package oil of a lower TBN can be as effective in fuel sulfur neutralization and overall performance as some oils with higher TBN values which have additives just for increased TBN. The used oil analysis can show these results.Consult the EMA Lubricating Oils Data Book, form SEBU6310 for a listing of oil brands meeting the CE requirements.For more information on oil and fuel sulfur content, refer to "Oil and Your Engine," form SEBD0640.Always consult with your Caterpillar dealer for the latest lubrication recommendations.Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.Cat Lubricating Grease
Caterpillar has greases for all applications.Cat Multipurpose Lithium Grease (MPGL) (non-extreme pressure)This NLGI No. 2 grade is recommended for light duty automotive type
Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. SPC is a Caterpillar designation for special synthetic oils, that do not contain viscosity improvers. The MIL specifications are U.S.A. Military Specifications. The definitions other than Caterpillar's will be of assistance in purchasing lubricants. The recommended oil viscosities can be found in the"Lubricant Viscosities" chart in this publication.The grease is classified by the National Lubricating Grease Institute (NLGI) based on the ASTM D217-68 Worked Penetration characteristics which are given a defined consistency number.Engine Lubricant Specification
Caterpillar has an oil formulation to provide maximum performance and life in your truck engine.Engine Oil (EO)
Cat Engine Oil (EO) is a lubricant that meets the performance requirements of today's newer truck engines as well as meeting the needs of earlier built truck engines. This oil has sufficient TBN and sulfated ash level to be effective in operation.* Cat Engine Oil (EO)This lubricating oil also meets the industry standards for both diesel and gasoline engine requirements.Cat Engine Oil is Caterpillar's recommendation for an engine oil specifically intended for use in mixed fleets. This oil is only for the convenience of having the same oil for gasoline and diesel engines.Alternate Oils
Failure to follow these recommendations for CE performance oils can cause shortened engine life due to carbon deposits or excessive wear.
If an oil other than Cat oil is to be used, the following oil specifications provide selection guidelines.If circumstances require the use of an oil other than the Cat Engine Oil, the following oil specifications can be used; API specification CE, CE/SF or CE/SG.Oil with these specifications may require shortened oil change periods as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The Caterpillar 20 times rule for TBN versus fuel sulfur is a general requirement, but it can be modified by used oil analysis. The effectiveness of an oil formulation will depend on the additive package. A balanced additive package oil of a lower TBN can be as effective in fuel sulfur neutralization and overall performance as some oils with higher TBN values which have additives just for increased TBN. The used oil analysis can show these results.Consult the EMA Lubricating Oils Data Book, form SEBU6310 for a listing of oil brands meeting the CE requirements.For more information on oil and fuel sulfur content, refer to "Oil and Your Engine," form SEBD0640.Always consult with your Caterpillar dealer for the latest lubrication recommendations.Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.Cat Lubricating Grease
Caterpillar has greases for all applications.Cat Multipurpose Lithium Grease (MPGL) (non-extreme pressure)This NLGI No. 2 grade is recommended for light duty automotive type