106873-3411 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068733411 220801671a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-3411 1068733411

HINO 220801671A 220801671a

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Service parts 106873-3411 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5940

3. GOVERNOR 105489-5001

4. SUPPLY PUMP 105237-0080

5. AUTOM. ADVANCE MECHANIS 105683-0400

6. COUPLING PLATE 105664-2170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7793

11. Nozzle and Holder 236002741B

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/24.5{250}

13. NOZZLE-HOLDER 105030-3581

14. NOZZLE

15. NOZZLE SET 105019-0541

Include in #1:

106873-3411 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106873-3411 1068733411

HINO 220801671A 220801671a

Zexel num

Bosch num

Firm num

Name

106873-3411
106873-3412

220801671A HINO

INJECTION-PUMP ASSEMBLY
F-2 * 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 131425-0020

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 4.2 4.14 4.2

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 8.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 146 150

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 148 145 151

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 8.45

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 138 134 142

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 7.6

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 117.5 112.5 122.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12 9 15

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_06

Adjusting point G

Rack position 8.75+-0. 1

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 153.5 147.5 159.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 710--

Advance angle deg. 0 0 0

Load 2/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 660

Advance angle deg. 0.3

Load 2/5

Timer adjustment_03

Pump speed r/min (760)

Advance angle deg. 2 1.7 2.3

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 2 1.7 2.3

Load 4/5

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 6.75 6.45 7.05

Load 5/5

Remarks
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=300r/min R1=3.4mm N2=1100r/min Q1=3mm3/st SXL=8.75+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Stopper bolt setting (4)Stopper bolt setting
----------
aa=1295r/min bb=700r/min
----------
a=14.5deg+-5deg b=(12deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=42mm
----------
a=39deg+-5deg b=41.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (set before setting excess fuel for starting) (2)Set the stopper bolt (apply red paint). (3)Use the hole at R = bb
----------
aa=12+0.5mm bb=37mm
----------
a=17.5deg+-5deg b=35deg+-5deg

0000001201

(1)Minimum - maximum speed specification (2)Variable speed specification
----------

----------
a=(14deg)+-5deg b=(30deg)

0000001501 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------

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:

Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. Following the directions in this manual will lower operating costs.The time needed for the engine to reach the normal mode of operation is usually less than the time taken for a walk-around-inspection of the engine.After the engine is started and the cold low idle operation is completed, the engine can be operated at rated speed and low power. The engine will reach normal operating temperature faster when operated at rated speed and low power demand than when idled at no load. Typically the engine should be up to operating temperature in a few minutes.Governors and Actuators
Your engine may be equipped with a:* full-range governor* Woodward PSG Governor* Woodward 1724 Actuator* Woodward 524 Actuator
PSG Actuator
1724/524 ActuatorWoodward Governors/Actuators are usually electrically operated from a control panel. The application is usually an EPG power generator set. On standby gen sets the governor may be set to operate only at Full Load Speed.Change Engine Speed
If equipped with a control panel, a RAISE/LOWER switch or a speed setting potentiometer is used to adjust the operating speed.Starting, Operating and Stopping Engines Equipped with Control Panels
For all information regarding the generator control panel used for starting, operating and stopping the engine, refer to the Engine Protection Devices Generator Set Control Panel topic in this publication or Caterpillar SR4 Generators and Control Panels, SEBU6150. Additional information and programming instructions are provided in the Service Manual for your specific control panel.Mechanical Governors (If Equipped)
Governor Control LeverYour engine may be equipped with a full-range governor. Most other manufacturers' engines have min-max type governors that only govern at high and low idle to prevent the engine from overspeeding or dying. With the min-max governor, the position of the speed lever determines the amount of fuel delivered to the engine.With the full-range governor, the position of the speed lever sets engine speed and helps hold a constant speed independent of load which makes operation easier.The governor control motor is a 24 volt motor which allows for engine speed control from a remote location through a governor RAISE/LOWER switch. This governor control switch is used with the optional EMCP II. Always increase engine speed to high idle before applying load.For information regarding initial checks and adjustments, refer to the Service Manual or contact your Caterpillar dealer.Driven Equipment Without Load
1. Move the governor control lever to half engine speed.2. Interrupted starts put excessive stress on the drive train and waste fuel. To get the driven equipment in motion, engage the clutch smoothly, with no load on the equipment. This should result in a smooth, easy start without increasing the engine speed above low idle or slipping the clutch. For generator sets, move the governor control to high idle (full load) position (1800 rpm for 60 Hz and 1500 rpm for 50 Hz).3. Apply the load and check the gauges and equipment for proper operation. Begin operating the engine at low load. After normal oil pressure