106671-3386 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066713386 220004080a


 

Information injection-pump assembly

ZEXEL 106671-3386 1066713386
HINO 220004080A 220004080a
106671-3386 INJECTION-PUMP ASSEMBLY
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Service parts 106671-3386 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106067-7510
3. GOVERNOR 105488-8170
4. SUPPLY PUMP 105217-1301
5. AUTOM. ADVANCE MECHANIS 105635-0121
6. COUPLING PLATE 105662-0500
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5031
11. Nozzle and Holder 23600-1221
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-5300
14. NOZZLE 105015-4640
15. NOZZLE SET

Include in #1:

106671-3386 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106671-3386 1066713386
HINO 220004080A 220004080a


Zexel num
Bosch num
Firm num
Name
106671-3386 
106671-3387 
 
220004080A  HINO
INJECTION-PUMP ASSEMBLY
EK100 * K

Calibration Data:

Adjustment conditions
Test oil
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
Overflow valve   134424-0920
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.3 3.24 3.3
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.75 60.25
Difference between angles 2
Cyl.1-2
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cal 1-3
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-5
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   A
Rack position   10.6
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   129 126 132
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   10.9
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   139.5 137.5 141.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   11.4
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   148 145 151
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   7+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   15 12 18
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   126.3 119.3 133.3
Fixing the lever   *
Timer adjustment
Pump speed r/min   1000--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   950
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1000
Advance angle deg.   1.5
Timer adjustment_04
Pump speed r/min   1050
Advance angle deg.   1.9 1.4 2.4
Timer adjustment_05
Pump speed r/min   1150
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106671-3386
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)RACK LIMIT
----------
DL=6.2-0.2mm
----------

Speed control lever angle

Test data 106671-3386
F:Full speed
----------

----------
a=3deg+-5deg

0000000901

Test data 106671-3386
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=27.5deg+-3deg

Stop lever angle

Test data 106671-3386
N:Pump normal S:Stop the pump.
----------

----------
a=15deg+-5deg b=64deg+-5deg

0000001501 GOVERNOR TORQUE CONTROL

Test data 106671-3386
Dr:Torque control stroke (A): Without torque control spring capsule 1. Adjustment procedures (1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting. 2. Procedures for adjustment (1)Remove the torque control spring capsule. (2)Operate the pump at approximately N1. (End of idling spring operation < N1.) (3)Tilt the lever to the full side. (4)Set so that R = RF. (5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window. (6)Adjust so that the torque control stroke Dr1 can be obtained. (7)Align N2 and N3 with the torque control spring capsule. 3. Final confirmation (1)After final confirmation, temporarily set the load lever to N = N1, R = idling position. (2)From this condition, increase speed to N = N4. (3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=550+-40r/min N3=930+-50r/min N4=950r/min RF=10.6mm Dr1=0.8mm Dr2=0+0.3mm
----------




Information:

USE FUEL CONSUMPTION, SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST. Performance of all lubrication and maintenance items in the Maintenance Schedule is the owners' responsibility.Daily
Walk-Around Inspection - Inspect for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner Indicator - Test Air Starting Motor (If Equipped) - Check/fill oiler bowlEvery 18 950 L (5000 gal) of Fuel or 125 Hours*
Scheduled Oil Sampling (S O S) Analysis - Obtain sample Engine Oil & Filters - Change oil and oil filter(s) Fuel System - Drain water/sediment Cooling System - Test Crankcase Breathers - Clean Engine Valve Lash (At First Oil Change Only) - Check/AdjustEvery 37 900 L (10,000 gal) of Fuel or 250 Hours*
Batteries - Clean/Check electrolyte level Belts, Hoses and Clamps - Inspect/Replace if necessary Engine Air Cleaners - Replace Engine Speed Sensors - Inspect/clean magnetic pick-upEvery 151 600 L (40,000 gal) of Fuel or 1000 Hours*
Engine Protection Devices - Inspect for proper operation (Check at least twice per year) Engine Valve Lash - Check/Adjust Turbochargers - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/checkEvery 341 100 L (90,000 gal) of Fuel or 2250 Hours*
Connecting Rod Bearings - ReplaceEvery 454 800 L (120,000 gal) of Fuel or 3000 Hours or Two Years*
Cooling System - Clean/Flush/replace thermostats and gasketsOverhaul Every 511 650 L (135,000 gal) of Fuel or 5400 Hours*
To minimize downtime and provide you with the lowest cost and highest value, Caterpillar recommends that the engine be overhauled before failure by scheduling an overhaul with your Caterpillar dealer. Refer to the Overhaul section in this manual on page 85. Top End Overhaul After Failure Overhaul Starting Motor - Inspect for proper operation Alternator - Inspect for proper operation Engine Speed Sensors - Inspect/clean/test*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/hours will vary depending on the proper application of your engine rating and adherence to recommended maintenance procedures.

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106671-3386  

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