106671-3387 ZEXEL 9 400 610 838 BOSCH INJECTION-PUMP ASSEMBLY 9400610838 1066713387 220004081a


 

Information injection-pump assembly

BOSCH 9 400 610 838 9400610838
ZEXEL 106671-3387 1066713387
HINO 220004081A 220004081a
106671-3387 INJECTION-PUMP ASSEMBLY
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Service parts 106671-3387 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106067-7510
3. GOVERNOR 105489-5040
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 23600-1221A
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-5300
14. NOZZLE 105015-4640
15. NOZZLE SET

Include in #1:

106671-3387 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 838 9400610838
ZEXEL 106671-3387 1066713387
HINO 220004081A 220004081a


Zexel num
Bosch num
Firm num
Name
106671-3387 
9 400 610 838 
220004081A  HINO
INJECTION-PUMP ASSEMBLY
EK100 K 14CA INJECTION PUMP ASSY PE6P,6PD PE

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   162 147 177
Overflow valve opening pressure kgf/cm2   1.65 1.5 1.8
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   *
Rack limit   *
Timer adjustment
Pump speed r/min   950
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   1.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   1.9 1.4 2.4
Timer adjustment_04
Pump speed r/min   1150
Advance angle deg.   4.5 4.2 4.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106671-3387
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)RACK LIMIT (5)Damper spring setting
----------
RT=1 TH=2.2mm
----------

Speed control lever angle

Test data 106671-3387
F:Full speed
----------

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

0000000901

Test data 106671-3387
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=27deg+-3deg

Stop lever angle

Test data 106671-3387
N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=64deg+-5deg

0000001501 GOVERNOR TORQUE CONTROL

Test data 106671-3387
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)r/min N3=(930)r/min N4=1000r/min RF=10.6mm Dr1=0.8mm Dr2=0+0.3mm
----------

Timing setting

Test data 106671-3387
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(0deg)




Information:

2. Maintain the oil level to the FULL mark (between the ADD and FULL RANGE zone) on the ENGINE STOPPED WITH OIL COLD side of the dipstick. Do not fill the crankcase above the FULL RANGE zone.3. Remove oil fill cap and add oil if necessary. DO NOT fill the crankcase above the FULL mark on the dipstick.
Do NOT overfill to reach above or to the top of the FULL mark on the dipstick.
Operating your engine when the oil level is above the FULL Range zone could cause your crankshaft to dip into the oil. If this occurs during engine operation, it could result in a loss of power and a possible alarm from high crankcase pressure. Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary filters, refer to the OEM or filter manufacturer's recommendations and instructions for all information regarding auxiliary oil filters.Estimating Oil Consumption
Oil consumption, along with fuel consumption and maintenance information, can be used to estimate total operating cost for your Caterpillar engine. It can also be used to estimate the capacity of a makeup oil system required to accommodate your maintenance intervals.Oil consumption is somewhat proportional to the percent load at which the engine is operating. The higher the percent load, the higher the amount of oil consumed per hour.The oil consumption rate, or BSOC (brake specific oil consumption), measure is grams/brake kW-hour (lb/bhp-hour). The BSOC varies depending on the load on your engine. The established typical mid-life BSOC values for your engine can be determined by contacting your Caterpillar dealer for assistance in determining typical oil consumption for your engine.Oil Consumption as an Overhaul Indicator
When an engine's oil consumption has risen to three times the initial (new) consumption rate due to normal wear, then the engine should be scheduled for overhaul. There may be a corresponding increase in blowby and also a slight increase in fuel consumption. Contact your Caterpillar dealer for assistance in determining typical oil consumption for your engine.Cooling System
Make sure you read and understand the information in the Safety and Cooling System Specifications sections of this manual before you proceed with maintenance of the cooling system.
Check Coolant Level
If Coolant is Low
Refer to the Cooling System Specifications section in this publication for all information pertaining to water, antifreeze and supplemental coolant additive requirements before performing this maintenance procedure.1. Stop the engine and allow the engine to cool before performing this maintenance procedure.2. Release vent valve (if equipped) slowly to relieve pressure. Remove filler cap and inspect condition of cap gasket. Replace cap if gaskets are damaged.3. Maintain the coolant level within 13 mm (1/2 inch) below the bottom of the fill pipe or to the proper level (upper half) on the sight glass (if equipped) by adding make-up coolant (antifreeze and water). Install the filler cap.4. Inspect for leaks or damaged piping. Make repairs if necessary.Air Cleaner Indicator
Typical air cleaner indicator shown.Check the service indicator (if equipped) mounted on the air cleaner. A colored piston showing

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106671-3387  
9 400 610 838 
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EK100
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