106671-8770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066718770 220204560a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-8770 1066718770

HINO 220204560A 220204560a

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Buy INJECTION-PUMP ASSEMBLY 106671-8770 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 106671-8770 1066718770

HINO 220204560A 220204560a

Zexel num

Bosch num

Firm num

Name

106671-8770
106671-8771

220204560A HINO

INJECTION-PUMP ASSEMBLY
K13C-T * 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 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 3.9 3.84 3.9

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 9.9

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 191 188 194

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 58.7 58.7

Boost pressure mmHg 440 440

Injection quantity adjustment_02

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 10.5 7.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 180

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-2.2

Boost pressure kPa 9.3 6.6 12

Boost pressure mmHg 70 50 90

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(9.9)

Boost pressure kPa 46.7 41.4 52

Boost pressure mmHg 350 310 390

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3.5 3.2 3.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=14 BCL=2.2+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

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a=6deg+-5deg b=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
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aa=0r/min bb=1-0.5mm
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a=10deg+-5deg b=70deg+-5deg

0000001501 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=9.9mm N1=1025r/min V1=3+-0.01V
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Timing setting

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

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

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Illustration 1 g06201989Certain Cat® Reman 3500 electronic fuel injectors may be marked with incorrect trim codes. Cat Reman 3500 electronic fuel injectors marked with trim code "2755" manufactured between 09 January 2017and 18 April 2017may be affected.The trim code is not correct for every injector. Refer to Illustration 1 for trim code identification. Serial numbers of suspect injectors range from (S/N: 1825569-1880788).Solution
Caterpillar is aware of this problem, but a permanent repair has not been identified. As an interim action, follow the below procedure:
All Reman 3500 electronic fuel injectors marked with trim code "2755" manufactured between 09 January 2017and 18 April 2017are suspect. Refer to Illustration 1.Caterpillar has created a tool which will help to identify injectors labeled with the incorrect trim code. Use the link below to download the file.https://cat.box.com/s/4fwh9nz0lwguh8vomifxj2rapqjc27e9
Enter the injector Serial Number in the spreadsheet downloaded. The spreadsheet will indicate whether the code is ok to use as is, or the spreadsheet will return the correct trim code.
Illustration 2 g06203882
If the trim code is incorrect, the injector must be relabeled. Use an engraving tool to cross out the original (incorrect) trim code (2755) and write the correct trim code on the injector tappet. Refer to Illustration 2.
Illustration 3 g06202000
Mark the box for each part that has been either reworked or verified to be correct, to identify that the parts are good to use. Refer to Illustration 3.
For individual injector replacements in engines, update the ECM with the correct trim code. Injectors must be marked with the correct trim code.Note: Do not return affected parts to Caterpillar. Use the procedure listed above to remark and use existing stock.Note: The issue has been resolved in the factory. Factory stock has been reworked and shipped. Parts in the distribution system are being sorted for return & rework.Note: Injector boxes have been marked with a large green dot to indicate that the injector has been sorted and marked correctly, or the trim code is correct.