106871-3991 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068713991 220005391a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-3991 1068713991

HINO 220005391A 220005391a

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Cross reference number

ZEXEL 106871-3991 1068713991

HINO 220005391A 220005391a

Zexel num

Bosch num

Firm num

Name

106871-3991

220005391A HINO

INJECTION-PUMP ASSEMBLY
EF750 * 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 134424-0820

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 7.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 123 121 125

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2+-0.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 141 138 144

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 142 136 148

Fixing the lever *

Injection quantity adjustment_04

Adjusting point -

Rack position 5.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point E

Rack position 7.9

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 131 128 134

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 10.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 150 160

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 7.7

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 124 118 130

Fixing the lever *

Timer adjustment

Pump speed r/min (860)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 4.75 4.45 5.05

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Damper spring setting: DL
----------
DL=3.8-0.5mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=22deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=50mm
----------
a=36deg+-3deg b=39deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Set the stopper bolt (apply red paint). (4)Free (at shipping)
----------
aa=12mm bb=3mm
----------
a=(15deg) b=48deg+-5deg c=26deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Mount the joint (B). (2)Select the shim (D) so that the rack limit's rack position is obtained at that time. (3)Install the rod (E) to the block (C). The distance between the pump end face and the rod (E) at rack limit must be L. 2. Rack sensor adjustment (-0020) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set at speed N. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=38-0.2mm N=1100r/min Ra=(8.2)mm
----------

Timing setting

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

----------
a=(80deg)

Information:

Information Release Memo REM03-28
Reman
September 2003 REMANUFACTURED FUEL INJECTORS FOR VARIOUS INDUSTRIAL, MACHINE, AND ON-HIGHWAY TRUCK APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured injector product line to include additional coverage for various 3126B, 3126E C10, C12, 3176, and 3196 Industrial, Machine, Marine and On-Highway Truck applications. Coverage The addition of these injectors provides dealers with an additional repair option to support various 3126B, 3126E, C10, C12, 3176, and 3196 Industrial, Machine and On-Highway Truck applications. Coverage is extensive so please consult your NPR or Reman Cross Reference for exact model coverage. Features And Benefits Cat? Remanufactured injectors offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warrantyBenefits
Improved reliability and performance
Customer access regardless of location
Consistent supportCore Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. Consult your Core Acceptance Guide for complete details.Warranty Please consult the appropriate warranty statement for your area.Core Management Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail.For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman Dealer website https://reman.cat.com If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0234 CATERPILLAR? ?2003 Caterpillar