106871-3600 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068713600 220004042b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-3600 1068713600

HINO 220004042B 220004042b

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Service parts 106871-3600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5650

3. GOVERNOR

4. SUPPLY PUMP 105237-1410

5. AUTOM. ADVANCE MECHANIS 105681-0021

6. COUPLING PLATE 105662-0790

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7040

11. Nozzle and Holder 23600-1602

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

13. NOZZLE-HOLDER 105031-7140

14. NOZZLE

105015-4700

15. NOZZLE SET

Include in #1:

106871-3600 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106871-3600 1068713600

HINO 220004042B 220004042b

Zexel num

Bosch num

Firm num

Name

106871-3600
106871-3602

220004042B HINO

INJECTION-PUMP ASSEMBLY
EF750 *

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 4.8 4.74 4.8

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 7.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 125.7 123.7 127.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 138.3 135.3 141.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 139.1 136.1 142.1

Fixing the lever *

Injection quantity adjustment_04

Adjusting point -

Rack position 5.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point E

Rack position 7.7

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 126 116 136

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 150 170

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position 7.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 126.4 123.4 129.4

Fixing the lever *

Timer adjustment

Pump speed r/min (875)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1075

Advance angle deg. 4.75 4.45 5.05

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Beginning of damper spring operation: DL
----------
SXL=8.4+0.2mm DL=3.8-0.5mm
----------

Speed control lever angle

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

----------
a=22deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=39deg+-5deg b=36deg+-3deg

Stop lever angle

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

----------
a=15deg+-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:

Illustration 1 g01068766
Inlet fuel line (fuel transfer pump to cylinder head) (1) Connector (2) Hose assembly (3) Fuel transfer pump
Remove connector (1) and hose assembly (2) from the fuel transfer pump (3). Refer to Illustration 1. Retain these parts for the reinstallation.
Illustration 2 g01068729
Outlet fuel line (fuel transfer pump to secondary fuel filter) (4) Adapter (5) Tee (6) Elbow (7) Hose assembly
Remove adapter (4), tee (5), elbow (6), and hose assembly (7) from the fuel transfer pump (3). Refer to Illustration 2. Retain these parts for the reinstallation.Note: Modifications to the tools may need to be made in order to reduce interference with engine components. Refer to Illustration 3.
Illustration 3 g01007381
Modified 2P-5494 crowfoot wrench
Illustration 4 g01068745
(3) Fuel transfer pump (8) Bolt (9) Bolt (10) Washer (11) Adapter (15) HEUI pump (21) Clip
Remove the bolt (8) and the clip (21) from the top of the fuel transfer pump. Refer to Illustration 4.
Remove the bolt (9) and the washer (10) from the bottom of the fuel transfer pump (3). Refer to Illustration 4.
Remove fuel transfer pump (3). Refer to Illustration 4.
Illustration 5 g01068776
(12) 45 ° adapter (13) Hose assembly (14) Straight connector (15) HEUI pump
Remove hose assembly (13) from 45 degree adapter (12) and straight connector (14) by using removal tool (A). Refer to Illustration 5.
Remove 45 degree adapter (12) from the HEUI pump (15). Remove straight adapter (14) from the cylinder head. Discard the parts. Refer to Illustration 5.Installation of the Engine Oil Lines Group
Illustration 6 g01068779
(16) 247-3755 Tube As (17) 6V-8636 Connector (18) 221-3494 O-Ring Seal (19) 214-7568 O-Ring Seal (20) 6V-8724 Elbow
Apply a light coat of oil to the O-rings (18) and (19) during installation. Install the O-ring (18) on