Information injection-pump assembly
ZEXEL
106873-3590
1068733590
HINO
220009400A
220009400a
Rating:
Service parts 106873-3590 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2910A
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/24.5{250}
14.
NOZZLE
Include in #1:
106873-3590
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106873-3590
1068733590
HINO
220009400A
220009400a
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
-
Rack position
12.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
119.5
116.5
122.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
8.5+-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
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.5)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
119.5
117.5
121.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
113
107
119
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
115
109
121
Fixing the lever
*
Timer adjustment
Pump speed
r/min
680--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
630
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
(700)
Advance angle
deg.
1
0.7
1.3
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
1
0.7
1.3
Timer adjustment_05
Pump speed
r/min
1100-50
Advance angle
deg.
4.5
4.2
4.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point I (Ra) can be obtained at full setting.]
(4)Stop lever's normal position setting: equivalent to R1
(5)Damper spring setting
----------
T1=AC70 Ra=(R1+1.9)mm R1=18mm
----------
----------
T1=AC70 Ra=(R1+1.9)mm R1=18mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=79mm
----------
a=12deg+-5deg b=26deg+-3deg
----------
aa=79mm
----------
a=12deg+-5deg b=26deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = approximately aa.
(2)Set the stopper screw. (After setting, apply red paint.)
(3)Speed = bb, rack position = cc
(4)Set the stopper screw. (After setting, apply red paint.)
(5)Use the hole above R = dd
----------
aa=18mm bb=0r/min cc=1.5+-0.3mm dd=35mm
----------
a=35deg+-5deg b=15deg+-5deg
----------
aa=18mm bb=0r/min cc=1.5+-0.3mm dd=35mm
----------
a=35deg+-5deg b=15deg+-5deg
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:
Rubber Damper (If Equipped)
The vibration damper can have a visual wobble (movement to the front and rear when in rotation) on the outer ring. This does not mean a replacement is necessary since some wobble of the outer ring is normal. To see if the amount of wobble is acceptable, or replacement is necessary, check the damper with the procedure in the Testing and Adjusting section of the Service Manual.The vibration damper has marks on the hub (1) and ring (2). These marks will indicate the condition of the vibration damper. If the marks are not in alignment, the rubber seal (3) between the ring and the hub has separated from the ring and/or hub. If the marks are not in alignment, install a new vibration damper. Refer to the Service Manual for the necessary replacement procedure.Air Compressor
Inspect/Check
Do not disconnect the air line from the air compressor governor without purging the air brake and auxiliary air systems.Failure to purge the air brake and auxiliary air systems before removing the air compressor could cause personal injury.
Inspect the air compressor as instructed by the OEM truck manufacturers' instructions or for more information on how to check your air compressor, refer to the Service Manual for this engine.If you decide to inspect your air compressor, be sure to observe the following actions. Visually check for fluid leaks and listen for air leaks. Release the air pressure in the air tank until the air pressure is zero. Remove discharge fittings and inspect compressor discharge port and discharge line for excessive carbon deposits. The discharge line must be cleaned or replaced and the compressor checked more thoroughly if there is excessive carbon build-up in either the discharge line or compressor discharge port.For more information on how to check your air compressor, refer to the OEM truck manufacturer's instructions or engine Service Manual.Engine Valve Lash
The procedures for engine valve lash should be performed according to the information in the Service Manual.
Check/Adjust
Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel.Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash.
Adjust the valve lash to the setting given in the chart above.Refer to the Service Manual or your Caterpillar dealer for the complete valve adjustment procedure.Bridge Adjustment
The valve bridge should be checked and/or adjusted each time valve lash is checked and/or adjusted. Valve and valve mechanism components do not always wear evenly which can allow the bridge to be out of adjustment.It is not necessary to remove the rocker arm shaft to adjust the valve bridges, but there must be clearance.Engine Valve Rotators
When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil or spray.
Observe rotation of valves with engine idling after setting the valve lash. Caterpillar recommends replacement of improperly operating valve rotators. An improperly operating valve rotator
The vibration damper can have a visual wobble (movement to the front and rear when in rotation) on the outer ring. This does not mean a replacement is necessary since some wobble of the outer ring is normal. To see if the amount of wobble is acceptable, or replacement is necessary, check the damper with the procedure in the Testing and Adjusting section of the Service Manual.The vibration damper has marks on the hub (1) and ring (2). These marks will indicate the condition of the vibration damper. If the marks are not in alignment, the rubber seal (3) between the ring and the hub has separated from the ring and/or hub. If the marks are not in alignment, install a new vibration damper. Refer to the Service Manual for the necessary replacement procedure.Air Compressor
Inspect/Check
Do not disconnect the air line from the air compressor governor without purging the air brake and auxiliary air systems.Failure to purge the air brake and auxiliary air systems before removing the air compressor could cause personal injury.
Inspect the air compressor as instructed by the OEM truck manufacturers' instructions or for more information on how to check your air compressor, refer to the Service Manual for this engine.If you decide to inspect your air compressor, be sure to observe the following actions. Visually check for fluid leaks and listen for air leaks. Release the air pressure in the air tank until the air pressure is zero. Remove discharge fittings and inspect compressor discharge port and discharge line for excessive carbon deposits. The discharge line must be cleaned or replaced and the compressor checked more thoroughly if there is excessive carbon build-up in either the discharge line or compressor discharge port.For more information on how to check your air compressor, refer to the OEM truck manufacturer's instructions or engine Service Manual.Engine Valve Lash
The procedures for engine valve lash should be performed according to the information in the Service Manual.
Check/Adjust
Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel.Hot engine components can cause burns. Allow additional time for the engine to cool before measuring/adjusting valve lash.
Adjust the valve lash to the setting given in the chart above.Refer to the Service Manual or your Caterpillar dealer for the complete valve adjustment procedure.Bridge Adjustment
The valve bridge should be checked and/or adjusted each time valve lash is checked and/or adjusted. Valve and valve mechanism components do not always wear evenly which can allow the bridge to be out of adjustment.It is not necessary to remove the rocker arm shaft to adjust the valve bridges, but there must be clearance.Engine Valve Rotators
When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil or spray.
Observe rotation of valves with engine idling after setting the valve lash. Caterpillar recommends replacement of improperly operating valve rotators. An improperly operating valve rotator