Information injection-pump assembly
ZEXEL
106971-3160
1069713160
HINO
220007580A
220007580a
Rating:
Service parts 106971-3160 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2450B
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
106971-3160
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106971-3160
1069713160
HINO
220007580A
220007580a
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
1-10-9-4
-3-6-5-8
-7-2
Pre-stroke
mm
4.8
4.74
4.8
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-10 deg. 27 26.75 27.25
Cal 1-10 deg. 27 26.75 27.25
Difference between angles 2
Cal 1-9 deg. 72 71.75 72.25
Cal 1-9 deg. 72 71.75 72.25
Difference between angles 3
Cal 1-4 deg. 99 98.75 99.25
Cal 1-4 deg. 99 98.75 99.25
Difference between angles 4
Cal 1-3 deg. 144 143.75 144.25
Cal 1-3 deg. 144 143.75 144.25
Difference between angles 5
Cal 1-6 deg. 171 170.75 171.25
Cal 1-6 deg. 171 170.75 171.25
Difference between angles 6
Cal 1-5 deg. 216 215.75 216.25
Cal 1-5 deg. 216 215.75 216.25
Difference between angles 7
Cal 1-8 deg. 243 242.75 243.25
Cal 1-8 deg. 243 242.75 243.25
Difference between angles 8
Cal 1-7 deg. 288 287.75 288.25
Cal 1-7 deg. 288 287.75 288.25
Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
126.4
124.4
128.4
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
128.4
122.4
134.4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.15
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
130
127
133
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
4.2+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
10
7
13
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
F
Rack position
9.2+-0.1
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
158
155
161
Fixing the lever
*
Remarks
Startup boost setting
Startup boost setting
Injection quantity adjustment_06
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
159
159
179
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
830--
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
1
0.7
1.3
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)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
(5)Excess fuel setting for starting: SXL
(6)Damper spring setting
----------
RT=1 TH=2.2mm N1=325r/min R1=4.2mm N2=1150r/min Q1=3mm3/st SXL=9.2+-0.1mm
----------
----------
RT=1 TH=2.2mm N1=325r/min R1=4.2mm N2=1150r/min Q1=3mm3/st SXL=9.2+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=19.5deg+-5deg
----------
----------
a=19.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=57.5mm
----------
a=28deg+-3deg b=17deg+-5deg
----------
aa=57.5mm
----------
a=28deg+-3deg b=17deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Set before governor adjustment.
(3)Set the stopper bolt (apply red paint).
----------
aa=16.5+0.5mm
----------
a=40deg+-5deg b=50deg+-5deg
----------
aa=16.5+0.5mm
----------
a=40deg+-5deg b=50deg+-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:
(1) Outer spring: Length under test force ... 27.4 mm (1.08 in.)Test force ... 180 9 N (40 2 lb.)Free length after test ... 45.2 mm (1.78 in.)(Damper coils of spring go toward cylinder head.)(2) Inner spring: Length under test force ... 23.88 mm (.940 in.)Test force ... 69 9 N (15.4 2 lb.)Free length after test ... 39.6 mm (1.56 in.)(Damper coils of spring go toward cylinder head.)(3) Valve guides: Inside diameter ... 9.507 to 9.543 mm (.3743 to .3757 in.)Outside diameter ... 15.921 to 15.933 mm (.6268 to .6273 in.)Parent bore diameter in cylinder head for valve guide ... 15.867 to 15.893 mm (.6247 to .6257 in.)Interference fit of guide in cylinder head ... 0.028 to 0.066 mm (.0011 to .0026 in.)Overall length of guide: Intake ... 57.94 mm (2.281 in.)Exhaust ... 61.11 mm (2.406 in.)Projection of guide above valve spring recess ... 15.09 mm (.594 in.)(4) Intake valve: Valve stem diameter ... 9.42 to 9.45 mm (.371 to .372 in.)Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in.)Maximum permissible clearance of valve in guide ... 0.13 mm (.005 in.)Valve head diameter ... 44.09 to 44.35 mm (1.736 to 1.746 in.) Grinding angles: Valve face angle ... 45°Valve seat angle ... 45°Valve head depth below cylinder head face: Minimum ... 1.02 mm (.040 in.)Maximum ... 1.27 mm (.050 in.)Service wear limit ... 1.52 mm (.060 in.)Overall length of valve ... 122.71 to 123.11 mm (4.831 to 4.847 in.)(5) Exhaust valve: Valve stem diameter ... 9.42 to 9.45 mm (.371 to .372 in.)Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in.)Maximum permissible clearance of valve in guide (all models) ... 0.15 mm (.006 in.)Valve head diameter ... 37.26 to 37.52 mm (1.467 to 1.477 in.)Grinding angles: Valve face angle ... 45°Valve seat angle ... 45°Valve head depth below cylinder head face: Minimum ... 1.02 mm (.040 in.)Maximum ... 1.27 mm (.050 in.)Service wear limit ... 1.52 mm (.060 in.)Overall length of valve ... 123.11 to 123.52 mm (4.847 to 4.863 in.)(6) Maximum permissible depth of bore to grind the flare of the valve seat ... 2.69 to 2.79 mm (.106 to .110 in.)(7) Angle to grind flare of valve seat ... 33° (8) Use the dimensions that follow to machine the recess into the cylinder head for valve seat inserts not already installed in the head. Intake: A ... 7.19 to 7.32 mm (.283 to .288 in.)B ... 51.219 to 51.245 mm (2.0165 to 2.0175 in.)C (Radius) ... 0.38 mm (.015 in.)Exhaust: A ... 9.53 to 9.65 mm (.375 to .380 in.)B ... 42.62 to 42.65 mm (1.678 to 1.679 in.)C (Radius) ... 0.38 mm (.015 in.)