Information injection-pump assembly
ZEXEL
106671-3560
1066713560
HINO
220002463A
220002463a

Rating:
Cross reference number
ZEXEL
106671-3560
1066713560
HINO
220002463A
220002463a
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 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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
130.5
127.5
133.5
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.
146
144
148
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.3
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
152.5
149.5
155.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
6.6+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
16
13
19
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
11+-0.5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
125
145
Fixing the lever
*
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
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Set the load lever's stop position so that R = aa (N = 0).
(3)RACK LIMIT
----------
DL=5.5-0.2mm aa=5.8+0.2mm
----------
----------
DL=5.5-0.2mm aa=5.8+0.2mm
----------
Speed control lever angle

F:Full speed
----------
----------
a=5deg+-5deg
----------
----------
a=5deg+-5deg
0000000901

F:Full load
I:Idle
S:Stop
(1)Rack position aa (pump speed bb r/min )
----------
aa=5.8+0.2mm bb=0r/min
----------
a=13deg+-3deg b=31deg+-3deg c=1deg+-5deg
----------
aa=5.8+0.2mm bb=0r/min
----------
a=13deg+-3deg b=31deg+-3deg c=1deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=64deg+-5deg
----------
----------
a=40deg+-5deg b=64deg+-5deg
0000001501 MICRO SWITCH
Switch adjustment
Adjust the bolt so that the lower lever position is obtained when the switch is turned ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=300+25r/min Ra=6.4mm
----------
----------
N1=300+25r/min Ra=6.4mm
----------
0000001601 GOVERNOR TORQUE CONTROL

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 N3, N4 and N5 using the torque control spring capsule.
----------
N1=500r/min N2=560+-50r/min N3=750+-30r/min N4=840+-20r/min N5=960+-50r/min RF=10.4mm Dr1=0.9mm
----------
----------
N1=500r/min N2=560+-50r/min N3=750+-30r/min N4=840+-20r/min N5=960+-50r/min RF=10.4mm Dr1=0.9mm
----------
Information:
Your truck may not have the same or all of the gauges as shown in the illustrations. The illustrations shown are of typical gauges.Gauges provide a "look" inside the engine. Be sure they are in good working order. You can determine what is the "normal" operating range by observing your gauges over a period of time.Noticeable changes in gauge readings are indicative of potential gauge or engine problems. This also applies to gauge readings that have changed significantly but are still within specifications. The cause of any sudden or significant change in the readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be between 40 and 88 psi (275 and 606 kPa) when the engine is running at rated engine speed, with SAE 15W-40 oil, at operating temperature. A lower pressure is normal at low idling speed.The "Check Engine" light will come on and a fault logged in the ECM system if oil pressure drops below 5 psi (35 kPa) at low idle rpm.
If no oil pressure is indicated, stop the engine. Engine damage can result.
Water Temperature - Indicates engine coolant temperature. It should normally indicate between 170°F (77°C) and 208°F (98°C). Maximum allowable temperature is 210°F (99°C) with the cooling system pressurized. Somewhat higher temperatures may occur under certain conditions. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge, have the charging system checked for malfunction. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding when downshifting, going downhill, etc., can result in serious damage to your engine.
Do not exceed 2300 rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. Electrically operated, it registers only when the key switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 23 psi (160 kPa) when equipped with a numerical gauge, the engine will not operate properly. A drop in fuel pressure usually indicates a dirty or plugged fuel filter. Service Hour Meter - Indicates the total number of clock hours the engine has operated.
If no oil pressure is indicated, stop the engine. Engine damage can result.
Water Temperature - Indicates engine coolant temperature. It should normally indicate between 170°F (77°C) and 208°F (98°C). Maximum allowable temperature is 210°F (99°C) with the cooling system pressurized. Somewhat higher temperatures may occur under certain conditions. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge, have the charging system checked for malfunction. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding when downshifting, going downhill, etc., can result in serious damage to your engine.
Do not exceed 2300 rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. Electrically operated, it registers only when the key switch is ON. Fuel Pressure - Indicates fuel pressure to the injection pump. The indicator should register in the NORMAL (green) range.If the indicator moves to the OUT position or registers below 23 psi (160 kPa) when equipped with a numerical gauge, the engine will not operate properly. A drop in fuel pressure usually indicates a dirty or plugged fuel filter. Service Hour Meter - Indicates the total number of clock hours the engine has operated.