Information injection-pump assembly
ZEXEL
106873-3100
1068733100
HINO
220007880A
220007880a
Rating:
Cross reference number
ZEXEL
106873-3100
1068733100
HINO
220007880A
220007880a
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
8.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
139.3
137.3
141.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.95+-0.
5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
133.1
129.1
137.1
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
F
Rack position
3.8+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
10.4
7.4
13.4
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
139
139
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
820--
Advance angle
deg.
0.7
0.4
1
Load
4/4
Timer adjustment_04
Pump speed
r/min
900+50
Advance angle
deg.
0.7
0.4
1
Load
3/4
Timer adjustment_05
Pump speed
r/min
1100-50
Advance angle
deg.
5.25
4.95
5.55
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
(3)Excess fuel setting for starting: SXL
(4)Damper spring setting
----------
N1=325r/min R1=3.8mm N2=1100r/min Q1=3mm3/st SXL=10.25+-0.1mm
----------
----------
N1=325r/min R1=3.8mm N2=1100r/min Q1=3mm3/st SXL=10.25+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=15.5deg+-5deg
----------
----------
a=15.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=39mm
----------
a=39deg+-5deg b=43.5deg+-3deg
----------
aa=39mm
----------
a=39deg+-5deg b=43.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa (at delivery), set before governor adjustment
(2)Set the stopper bolt (apply red paint).
(3)Use the pin at R = bb
(4)Lever free
----------
aa=12+-0.1mm bb=37mm
----------
a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg
----------
aa=12+-0.1mm bb=37mm
----------
a=(9deg)+-5deg b=9deg+-5deg c=35deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
Commercial Oils
If oils other than Caterpillar oils are used, the following oil specifications provide guidelines for the selection of commercial products.* API specifications CF-4, CF-4/SF, or CF-4/SG
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
Lubricant Viscosity Recommendations
The proper SAE grade of oil to select is determined by the minimum outside temperature at which the engine will be started and the maximum outside temperature in which the engine will be operating. This recommendation is to ensure the correct viscosity is used until the next oil change.The recommendation would be to use the highest viscosity oil possible. Even though the ambient temperature may be low, operating engines can still be subjected to normal oil temperatures because of regulated temperature components. The higher viscosity oils will provide better protection to all components which it contacts during the full operating cycle.The use of API CF-4 multi-viscosity oils is recommended because of full protection through a wider temperature range. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly. Air Starting Motor Oiler
A lubricator should be used with the starting system.* Use 10 weight non-detergent engine oil above 0°C (32°F) or* diesel fuel or kerosene at temperatures below 0°C (32°F).Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society of Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information. Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur. Therefore, the Caterpillar requirements reflect this value of 10 times instead of the previous 20 times for oil TBN when related to fuel sulfur for Cat DI engines and API CF-4 oils. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and
If oils other than Caterpillar oils are used, the following oil specifications provide guidelines for the selection of commercial products.* API specifications CF-4, CF-4/SF, or CF-4/SG
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
Lubricant Viscosity Recommendations
The proper SAE grade of oil to select is determined by the minimum outside temperature at which the engine will be started and the maximum outside temperature in which the engine will be operating. This recommendation is to ensure the correct viscosity is used until the next oil change.The recommendation would be to use the highest viscosity oil possible. Even though the ambient temperature may be low, operating engines can still be subjected to normal oil temperatures because of regulated temperature components. The higher viscosity oils will provide better protection to all components which it contacts during the full operating cycle.The use of API CF-4 multi-viscosity oils is recommended because of full protection through a wider temperature range. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly. Air Starting Motor Oiler
A lubricator should be used with the starting system.* Use 10 weight non-detergent engine oil above 0°C (32°F) or* diesel fuel or kerosene at temperatures below 0°C (32°F).Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society of Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information. Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis or the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur. Therefore, the Caterpillar requirements reflect this value of 10 times instead of the previous 20 times for oil TBN when related to fuel sulfur for Cat DI engines and API CF-4 oils. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and