Information injection-pump assembly
ZEXEL
106873-3131
1068733131
HINO
220007971A
220007971a
Rating:
Cross reference number
ZEXEL
106873-3131
1068733131
HINO
220007971A
220007971a
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
(5)Variable speed specification: idling adjustment
(6)Main 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
I:Idle
(1)Stopper bolt setting
----------
----------
a=15.5deg+-5deg b=(14deg)+-5deg
----------
----------
a=15.5deg+-5deg b=(14deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=42mm
----------
a=39deg+-5deg b=43.5deg+-3deg
----------
aa=42mm
----------
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:
Water Pump Seal
Over concentration of coolant additive (Conditioner), mineral deposits from hard water or cooling system contamination can accelerate the wear on the water pump coolant seal. The cooling system maintenance interval provides an opportunity to inspect and replace the water pump seal if necessary to reduce coolant leakage.Dispose of used engine coolant in an environmentally correct way or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant and for information regarding disposal and recycling of used coolant.4. Clean and install all drain plugs and/or close the cooling system drain valve(s).Replace Thermostat, Gaskets and Seal
Refer to the Service Manual for detailed instructions regarding Disassembly and Assembly of the Cooling System. Repeat procedure for both thermostat housing assemblies.Replacing the thermostats prior to failure is a recommended preventive maintenance practice because it reduces the chances for cooling system problems and unscheduled downtime.
Failure to replace your thermostats on a regularly scheduled basis could cause severe engine damage.
If replacing thermostats ONLY, drain the coolant from the cooling system to a level below the thermostat housing.5. Disconnect hose assemblies from radiator and each thermostat housing assembly.6. Remove bolts and thermostat housing assembly.7. Remove the gasket, thermostat and seal from each housing.
Former thermostats may be used, if they meet test specifications as described in the Service Manual (and are not damaged or have excessive buildup of deposits).
The thermostats can be reused if they are tested and meet the test specifications in the Service Manual.Flush
8. Refill the cooling system with clean water mixed with the proper concentration (six to ten percent) of Fast Acting-Type Caterpillar Cooling System Cleaner (4C4611). Tighten cooling system vent cap. For proper cooling system maintenance cleaning, refer to label directions for the type of Caterpillar Cooling System Cleaner used in your cooling system.9. Start and run (operate) the engine to circulate fluid in the cooling system.10. Stop the engine and allow to cool. Loosen cooling system vent cap and drain plugs.11. Drain the cleaning solution. Flush the cooling system with clean water and a neutralizing solution until draining water is clear. Clean and install all drain plugs and/or close the drain valve. Sodium Carbonate crystals at a rate of 250 grams per 40 liters of water (1/2 pound per 10 U.S. gallon of water) may be used as a neutralizer. Repeat Steps 8 thru 11 if necessary until the draining water is clear.Install Thermostat
Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed.If the thermostat is installed wrong, it will cause the engine to overheat.
Inspect gaskets before assembly and replace if worn or damaged.12. Install a new seal in each thermostat housing and install new thermostats.13. Install a new gasket and the thermostat housing on the engine cylinder head.14. Install the cooling system connections and tighten the hose or piping clamps.Fill
All water is corrosive at engine operating temperature. The cooling system
Over concentration of coolant additive (Conditioner), mineral deposits from hard water or cooling system contamination can accelerate the wear on the water pump coolant seal. The cooling system maintenance interval provides an opportunity to inspect and replace the water pump seal if necessary to reduce coolant leakage.Dispose of used engine coolant in an environmentally correct way or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Caterpillar to reclaim the used coolant and for information regarding disposal and recycling of used coolant.4. Clean and install all drain plugs and/or close the cooling system drain valve(s).Replace Thermostat, Gaskets and Seal
Refer to the Service Manual for detailed instructions regarding Disassembly and Assembly of the Cooling System. Repeat procedure for both thermostat housing assemblies.Replacing the thermostats prior to failure is a recommended preventive maintenance practice because it reduces the chances for cooling system problems and unscheduled downtime.
Failure to replace your thermostats on a regularly scheduled basis could cause severe engine damage.
If replacing thermostats ONLY, drain the coolant from the cooling system to a level below the thermostat housing.5. Disconnect hose assemblies from radiator and each thermostat housing assembly.6. Remove bolts and thermostat housing assembly.7. Remove the gasket, thermostat and seal from each housing.
Former thermostats may be used, if they meet test specifications as described in the Service Manual (and are not damaged or have excessive buildup of deposits).
The thermostats can be reused if they are tested and meet the test specifications in the Service Manual.Flush
8. Refill the cooling system with clean water mixed with the proper concentration (six to ten percent) of Fast Acting-Type Caterpillar Cooling System Cleaner (4C4611). Tighten cooling system vent cap. For proper cooling system maintenance cleaning, refer to label directions for the type of Caterpillar Cooling System Cleaner used in your cooling system.9. Start and run (operate) the engine to circulate fluid in the cooling system.10. Stop the engine and allow to cool. Loosen cooling system vent cap and drain plugs.11. Drain the cleaning solution. Flush the cooling system with clean water and a neutralizing solution until draining water is clear. Clean and install all drain plugs and/or close the drain valve. Sodium Carbonate crystals at a rate of 250 grams per 40 liters of water (1/2 pound per 10 U.S. gallon of water) may be used as a neutralizer. Repeat Steps 8 thru 11 if necessary until the draining water is clear.Install Thermostat
Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed.If the thermostat is installed wrong, it will cause the engine to overheat.
Inspect gaskets before assembly and replace if worn or damaged.12. Install a new seal in each thermostat housing and install new thermostats.13. Install a new gasket and the thermostat housing on the engine cylinder head.14. Install the cooling system connections and tighten the hose or piping clamps.Fill
All water is corrosive at engine operating temperature. The cooling system