106971-3082 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069713082 220005592a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-3082 1069713082

HINO 220005592A 220005592a

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Buy INJECTION-PUMP ASSEMBLY 106971-3082 zexel genuine, new aftermarket engine parts with delivery

Service parts 106971-3082 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5350

3. GOVERNOR 105489-0901

4. SUPPLY PUMP 105237-1670

5. AUTOM. ADVANCE MECHANIS 105639-1150

6. COUPLING PLATE 105664-0461

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7480

11. Nozzle and Holder 23600-1910

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105031-7200

14. NOZZLE 105015-7390

15. NOZZLE SET

Include in #1:

106971-3082 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-3082 1069713082

HINO 220005592A 220005592a

Zexel num

Bosch num

Firm num

Name

106971-3082

220005592A HINO

INJECTION-PUMP ASSEMBLY
V22C * K 14CE PE10P PE

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 1-10-9-4 -3-6-5-8 -7-2

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-10 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-9 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-4 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-3 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-6 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-8 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-7 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 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. 127.4 125.4 129.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 123.1 120.1 126.1

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 142 139 145

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point F

Rack position 4.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 5 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 180 180 200

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min (875)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 4.75 4.25 5.25

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)RACK LIMIT (4)Damper spring setting: DL
----------
RT=0.8 TH=2.4mm DL=3.9-0.5mm
----------

Speed control lever angle

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

----------
a=15deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=61mm
----------
a=33deg+-3deg b=17deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=16deg+-5deg b=64deg+-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)

Information:

PROBLEM
The front suspension A-Frame bearing may not be receiving an adequate amount of grease on machines that are equipped with the factory fitted Automatic Lubrication System. An inadequate amount of grease supply to the bearing does not promote purging of grease through the joint, especially in severe applications. This may result in premature wear of the bearing.
A larger sized injector is available which increases the amount of grease that is supplied to the bearing
Note: This service letter covers machines with factory fitted Automatic Lubrication Systems only. Dealer installed Automatic Lubrications Systems are not covered.
AFFECTED PRODUCT
Model Identification Number
735B L4D00368, 372, 375-380, 384-403
T4P00253-00258, 268-271, 275-277, 280-282, 284-286, 290-292, 302, 304
740B L4E00374-00378, 380, 385, 390, 392-393, 401-403, 407-408, 411, 419, 429-430, 433-437, 440, 443-449, 451, 453-455, 459, 465, 469, 471, 478, 480, 489, 492, 505, 511, 517, 522-529, 533, 535, 543, 549-550, 558, 560, 563, 567, 570, 575-576, 584, 592, 609-610, 612-616, 622, 624-627, 633-634, 643, 666, 670-673, 679-682, 687-694, 701-702, 708, 710, 712, 715-716, 722, 726-728, 734-735, 738, 741-743, 745-746, 755-757, 760, 763, 768, 774, 777, 779, 784-785, 788-789, 792, 796-799, 802-803, 805, 810, 812-813, 816-817, 821-822, 826-828, 833, 837, 842, 851, 853, 857, 861, 865-867, 881-882, 885, 887, 890-891, 896, 900, 903-904, 909-910, 912-915, 917-919, 921, 924-925, 927, 932-933, 945-950, 955-957, 962-971, 976-980, 985
T4R00267-00273, 278, 282-283, 289, 294, 299-300, 309-310, 322-323, 327, 339, 342, 348, 352, 354, 356, 359-360, 362-369, 371, 376-377, 393, 406, 423, 427, 431-432, 450, 518, 539-540, 543-546, 550, 557, 568, 581-582, 587-590
740B EJ L4F00383-00388
T4S00272-00274, 276-279, 282, 289-290, 296-299, 301, 304-309, 311
PARTS NEEDED
Qty
Part Number Description
1 1926212 INJECTOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
See attached rework procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-8000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
(1). Remove the grease injector from the manifold that is located on the right side of the front chassis. See Image 1.1.1 for location.
(2). Install new 192-6212 Injector.
(3). Purge new injector by pressing the Test Switch on the Auto Lube pump. See Image 1.1.2 for test switch location.
(4). Install the grease line to the injector.
Image1.1.1
Image1.1.2