Information injection-pump assembly
ZEXEL
106971-3181
1069713181
HINO
220008031A
220008031a
Rating:
Service parts 106971-3181 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2480E
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/24.5{250}
14.
NOZZLE
Include in #1:
106971-3181
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106971-3181
1069713181
HINO
220008031A
220008031a
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
4.3
4.24
4.3
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
9.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
158.5
156.5
160.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
162
156
168
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
165.5
159.5
171.5
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
9.35
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
145
142
148
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
4.1+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12.5
9.5
15.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
10.2+-0.
1
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
186
182
190
Fixing the lever
*
Remarks
Startup boost setting
Startup boost setting
Injection quantity adjustment_07
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
190
190
200
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Injection quantity adjustment_08
Adjusting point
H
Rack position
9.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
164.5
160.5
168.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
580--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
530
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
(620--)
Advance angle
deg.
1.5
1.2
1.8
Load
4/4
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
1.5
1.2
1.8
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)Tolerance for racks not indicated: +-0.05mm.
(2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
(3)Excess fuel setting for starting: SXL
(4)Damper spring setting
----------
N1=300r/min R1=4.1mm N2=1100r/min Q1=3mm3/st SXL=10.2+-0.1mm
----------
----------
N1=300r/min R1=4.1mm N2=1100r/min Q1=3mm3/st SXL=10.2+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=13.5deg+-5deg
----------
----------
a=13.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole to the left of R = aa
(2)Stopper bolt setting
----------
aa=56mm
----------
a=33.5deg+-3deg b=23deg+-5deg
----------
aa=56mm
----------
a=33.5deg+-3deg b=23deg+-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) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Use again minimum load at length under test force ... 217 N (48.83 lb)Length of spring at valve open position ... 32.28 mm (1.271 in)Use again minimum load at valve open position ... 658 N (148.5 lb)Free length after test ... 52.07 mm (2.05 in)Outside diameter ... 35.21 mm (1.386 in)spring must not be bent more than ... 1.82 mm (.072 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head. Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in) (4) Valve lip thickness: 6N9916 Exhaust Valve Use again minimum ... 2.96 mm (.106 in)7N753 Exhaust Valve Use again minimum ... 2.44 mm (.096 in)7N572 Intake Valve Use again minimum ... 2.69 mm (.106 in)6N9915 Intake Valve Use again minimum ... 2.44 mm (.096 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4° (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1°(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 or 7N753 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 6N9915, 2W2620 or 7N752 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°Procedure to Check Intake Valve Timing
SMCS Code: 1105-5311. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the clearance is not in this range adjust the clearance to .038 mm (.015 in).2. Mark
SMCS Code: 1105-5311. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the clearance is not in this range adjust the clearance to .038 mm (.015 in).2. Mark