Information injection-pump assembly
ZEXEL
106873-3401
1068733401
HINO
220008971A
220008971a
Rating:
Service parts 106873-3401 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2741B
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/24.5{250}
14.
NOZZLE
Include in #1:
106873-3401
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106873-3401
1068733401
HINO
220008971A
220008971a
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
131425-0020
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
4.2
4.14
4.2
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
8.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
146.5
144.5
148.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.45
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
146.5
143.5
149.5
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
8.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
140.5
136.5
144.5
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
7.8
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
120
115
125
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
F
Rack position
3.8+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
12
9
15
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_06
Adjusting point
G
Rack position
8.9+-0.1
Pump speed
r/min
330
330
330
Average injection quantity
mm3/st.
155
149
161
Fixing the lever
*
Remarks
Startup boost setting
Startup boost setting
Timer adjustment
Pump speed
r/min
710--
Advance angle
deg.
0
0
0
Load
2/5
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
660
Advance angle
deg.
0.3
Load
2/5
Timer adjustment_03
Pump speed
r/min
(760)
Advance angle
deg.
2
1.7
2.3
Load
5/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
2
1.7
2.3
Load
4/5
Timer adjustment_05
Pump speed
r/min
1100-50
Advance angle
deg.
6.75
6.45
7.05
Load
5/5
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)Stop lever's normal position setting: R1
(5)Excess fuel setting for starting: SXL
(6)When air cylinder is operating.
(7)Damper spring setting
(8)Set idle at point K (N = N1, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
----------
RT=0.8 TH=2.5mm R1=12+0.5mm SXL=8.9+-0.1mm N1=300r/min R2=3.8mm N2=1100r/min Q1=3mm3/st
----------
----------
RT=0.8 TH=2.5mm R1=12+0.5mm SXL=8.9+-0.1mm N1=300r/min R2=3.8mm N2=1100r/min Q1=3mm3/st
----------
Speed control lever angle
F:Full speed
----------
----------
a=20deg+-5deg
----------
----------
a=20deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
(3)Set point I (at air cylinder operation)
----------
aa=90mm
----------
a=36.5deg+-3deg b=(1deg)+-3deg c=10deg+-5deg
----------
aa=90mm
----------
a=36.5deg+-3deg b=(1deg)+-3deg c=10deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa (set before setting excess fuel for starting)
(2)Set the stopper bolt (apply red paint).
(3)Use the hole at R = bb
----------
aa=12+0.5mm bb=37mm
----------
a=20deg+-5deg b=35deg+-5deg
----------
aa=12+0.5mm bb=37mm
----------
a=20deg+-5deg b=35deg+-5deg
0000001501 LEVER
1. Air cylinder adjustment
(1)With the load lever in the idle position, temporarily set the distance between the load lever A and the air cylinder D at approximately L.
(2)Set N1 and apply P1 to the air cylinder D.
(3)Adjust set bolt (D) to obtain R1 at the same speed.
(4)Lock using nut C.
(5)Apply positive pressure several times.
(6)Confirm that the load lever A returns to the idling position N2 at pressure P2.
(7)Also at P1 confirm R1 (N1).
----------
L=5mm R1=3.8mm N1=275r/min N2=250r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
----------
L=5mm R1=3.8mm N1=275r/min N2=250r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
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:
Gauges provide indications of engine performance. Be sure they are in good working order. You can determine what is the "normal" operating range by observing the gauges over a period of time.Noticeable changes in gauge readings indicate potential gauge or engine problems. This also applies to gauge readings that have changed significantly, but are still within specifications. The cause of any sudden or significant change in gauge readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be greatest after starting a cold engine. Oil pressure should read between 240 and 480 kPa (35 and 70 psi) when: the engine is running at rated engine speed with SAE 10W30 oil, and at operating temperature. A lower pressure is normal at low idling speed.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 77°C (170°F) and 98°C (209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of service meter units or clock hours the engine has operated.
Engine damage can result if the engine is operated with no oil pressure gauge reading. If no pressure is indicated, stop the engine.
Jacket Water Temperature - Indicates engine coolant temperature. It should normally indicate between 77°C (170°F) and 98°C (209°F). Higher temperatures may occur under certain conditions. Maximum allowable temperature is 99°C (210°F) with the cooling system pressurized. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).Check the charging system for malfunction if, during operation, the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding can seriously damage your engine.
Do not exceed "bare engine high idle" rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. The electrically operated fuel level gauge registers only when the START/STOP (ignition key) switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 160 kPa (23 psi) when equipped with a numerical gauge, the engine will not operate properly. In most cases this is caused by a plugged fuel filter. Service Hour Meter - Indicates the total number of service meter units or clock hours the engine has operated.