106871-3210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068713210 220001306a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-3210 1068713210

HINO 220001306A 220001306a

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Service parts 106871-3210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5111

3. GOVERNOR 105488-7250

4. SUPPLY PUMP 105237-1121

5. AUTOM. ADVANCE MECHANIS 105636-0220

6. COUPLING PLATE 105662-0500

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4521

11. Nozzle and Holder 23600-1212

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

13. NOZZLE-HOLDER 105031-5350

14. NOZZLE 105015-4110

15. NOZZLE SET

Include in #1:

106871-3210 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-3210 1068713210

HINO 220001306A 220001306a

Zexel num

Bosch num

Firm num

Name

106871-3210

220001306A HINO

INJECTION-PUMP ASSEMBLY
EF700 * 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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4 3.9 4

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-6 deg. 90 89.5 90.5

Difference between angles 3
Cyl.1-2 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-7 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-4 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-3 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 9.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 114.6 111.6 117.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 115 113 117

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.2

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 141.2 138.2 144.2

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 6.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 13.7 10.7 16.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 50 50 50

Average injection quantity mm3/st. 122 112 132

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_06

Adjusting point F

Rack position -

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 0

Fixing the lever *

Timer adjustment

Pump speed r/min 950+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Set idle at point G (N = N1, R = R1) and confirm that the fuel injection quantity at point F (N = N2) does not exceed Q1. (3)Set the load lever's stop position so that R = aa (N = 0). (4)Excess fuel setting for starting: SXL
----------
DL=5.4-0.2mm N1=300r/min R1=5.4mm N2=1000r/min Q1=0mm3/st aa=5.8+0.2mm SXL=10.2+0.2mm
----------

Speed control lever angle

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

----------
a=4deg+-5deg

0000000901

F:Full load I:Idle S:Stop
----------

----------
a=32deg+-5deg b=33deg+-3deg c=19deg+4deg-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325-25r/min Ra=6.4mm
----------

Information:

Illustration 4 g01621593
(4) The process of crimping has been improved in the location that is shown. The Fifth Improvement
The length of the bolts that secure the fuel transfer pump to the HEUI pump body have increased. The torques on the bolts that secure the transfer pump to the HEUI pump body have also increased in order to improve durability.
HEUI pumps that have been returned from the field have been inspected and broken bolts that connect the fuel transfer pump to the main HEUI pump were found.
The major symptom that is related to this issue is an oil leak between the fuel transfer pump and the HEUI pump.
The bolts that make this connection were lengthened as well as the torques were increased in order to provide a better connection.
This improvement was effective with the following part numbers: 319-0607, 319-0674, 319-0675, 319-0676, 319-0677, 319-0678, 319-0622, 319-0610 and 319-0680
Illustration 5 g01621594
(5) Location of the three bolts that have been lengthened and increased torques have been applied. Note: The applications that utilize an electric fuel transfer pump also have this improvement for the cover that goes in place of the mechanical fuel transfer pump.Note: Refer to Special Instruction , REHS3830 for the following items: parts information, installation of parts and torque procedures that are related to this improvement.All current remanufactured part numbers are being built with the latest improvements. A list of all the current new part numbers and the part numbers of the remanufactured equivalent can be seen below.
Table 1
Current New Part Numbers Remanufactured Equivalent
319-0607 -
319-0674 -
319-0675 10R7145
319-0676 10R7146
319-0677 10R7147
319-0678 10R7148
319-0622 -
319-0610 10R3044
319-0680 - Note: All part numbers that are referenced in this publication were current on 15 July 2008. Part numbers are subject to a change.
Table 2
New Part Numbers Serial Number Prefixes that Use the Part Numbers
319-0607 S/N:532, ; S/N:551, ; S/N:511, ; S/N:521, ; S/N:522, ; S/N:525, ; S/N:535, ; S/N:541, ; S/N:545, ; S/N:552, ; S/N:B3T, ; S/N:B9D, ; S/N:B9M, ; S/N:D9G
319-0674 S/N:C7D, ; S/N:C7P, ; S/N:C7Z, ; S/N:M7A
319-0675 S/N:HEP, ; S/N:BTM, ; S/N:CAP, ; S/N:CGZ, ; S/N:GAG, ; S/N:HAA, ; S/N:JAB, ; S/N:JCD, ; S/N:KDD, ; S/N:MCA, ; S/N:CYA, ; S/N:GKX, ; S/N:JNK, ; S/N:RBH, ; S/N:MKM, ; S/N:MSD, ; S/N:MSL, ; S/N:CEX, ; S/N:CEH, ; S/N:BCP, ; S/N:CLJ, ; S/N:AEM, ; S/N:AFM, ; S/N:BLE, ; S/N:BLT, ; S/N:BMK, ; S/N:BNL, ; S/N:BPM, ; S/N:BRJ, ; S/N:CAD, ; S/N:FDT, ; S/N:ACJ, ; S/N:ADE, ; S/N:BNC, ; S/N:BPP, ; S/N:BPZ, ; S/N:AAX, ; S/N:AGM, ; S/N:BMJ, ; S/N:BMY, ; S/N:BPS, ; S/N:BRZ, ; S/N:AEP, ; S/N:DAE, ; S/N:L5J, ; S/N:BRE
319-0676 S/N:101, ; S/N:102, ; S/N:103, ; S/N:104, ; S/N:125, ; S/N:202, ; S/N:301, ; S/N:302, ; S/N:AMZ, ; S/N:B1K, ; S/N:B2L, ; S/N:B3M, ; S/N:B4N, ; S/N:CAP, ; S/N:CBK, ; S/N:D3C, ; S/N:DKY
319-0677 S/N:ECH, ; S/N:AWN, ; S/N:CJX, ; S/N:JKR, ; S/N:JLS, ; S/N:JGK, ; S/N:BYE, ; S/N:T2D, ; S/N:DFP, ; S/N:SYM, ; S/N:JJG, ; S/N:LAB, ; S/N:EJC, ; S/N:KJR, ; S/N:PEH, ; S/N:CJM, ; S/N:GBR, ; S/N:KDG, ; S/N:KBE, ; S/N:DBH, ; S/N:SCR, ; S/N:GPB, ; S/N:PKE, ; S/N:C7K, ; S/N:C9M, ;