106971-3100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069713100 220005621a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-3100 1069713100

HINO 220005621A 220005621a

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Buy INJECTION-PUMP ASSEMBLY 106971-3100 zexel genuine, new aftermarket engine parts with delivery

Service parts 106971-3100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5340

3. GOVERNOR 105489-0950

4. SUPPLY PUMP 105237-1670

5. AUTOM. ADVANCE MECHANIS 105681-0280

6. COUPLING PLATE 105664-0470

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7480

11. Nozzle and Holder

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:

106971-3100 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106971-3100 1069713100

HINO 220005621A 220005621a

Zexel num

Bosch num

Firm num

Name

106971-3100

220005621A HINO

INJECTION-PUMP ASSEMBLY
V21C * 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 1-10-9-4 -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 7.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 123.3 121.3 125.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 119.4 116.4 122.4

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 133.7 130.7 136.7

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

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 F

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 (825)

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)RACK LIMIT (2)Damper spring setting: DL
----------
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: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 delivery)
----------
aa=3-0.5mm bb=11.7mm
----------
a=(30deg) b=3deg+-5deg c=26deg+-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:

Model Identification Number
773G JWS00162-00208
773G OEM T5T00101
775G MJS00273-00322
PARTS NEEDED
Qty
Part Number Description
2 1R1808 FILTER-LUBE
12 8S9191 BOLT
4 3460335 CLAMP-BAND
12 3594040 INJECTOR GP-FUEL
1 BULK_OIL DEO-ULS (95 Liters)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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
If excessive fuel dilution of engine oil is found reference the following documents to determine the cause of fuel dilution.
Special Instruction, REHS3007,"Determining the Cause of Fuel Dilution of Engine Oil"
Troubleshooting, KENR9795, "C27 and C32 Engines for Caterpillar Built Machines"
Once an injector(s) has been identified as having a cracked/leaking injector body, replace the failed injector(s). Inspect the remaining good injector serial numbers with Cat ET, (Injector Serial Numbers = Injector trim file name, (ie 6Cxxxxxxxxxx.trm)). If the remaining injector serial numbers fall within the serial number range below, replace at the same time. Refer to Image 1 for the serial number
location on the top of the electronic unit injector.
Injector Serial Numbers
6C0018656646 through 6C0021994059
If an injector failure occurs on either of the rear two cylinders (right and/or left hand bank) the exhaust piping going from the turbo to the CEM will have to be removed. 346-0335 Exhaust Clamp cannot be reused and MUST be replaced with a new clamp. Refer to REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for the proper installation and removal procedure. Refer to Image 2 for clamp location.
The 8S-9191 Injector Hold Down Bolts must be replaced.
Refer to Disassembly and Assembly, RENR9217 for the removal, installation, and tightening procedures.
After the engine is reassembled, change the engine oil and filters.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 10.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.