106971-3070 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1069713070 220004281a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106971-3070 1069713070

HINO 220004281A 220004281a

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Cross reference number

ZEXEL 106971-3070 1069713070

HINO 220004281A 220004281a

Zexel num

Bosch num

Firm num

Name

106971-3070
106971-3071

220004281A HINO

INJECTION-PUMP ASSEMBLY
EV700 *

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 3.94 4

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 9.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 124 122 126

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 113 110 116

Max. variation between cylinders % 0 -5 5

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. 148 142 154

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point H

Rack position 12.6+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160 180

Fixing the lever *

Rack limit *

Injection quantity adjustment_05

Adjusting point I

Rack position 6.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 8 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 950

Advance angle deg. 0.75 0.75 0.75

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 4.25 3.95 4.55

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Set the lever at delivery. (3)Damper spring setting: DL
----------
DL=4.4-0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle (1)Set the lever at delivery (set the stopper bolt).
----------

----------
a=22deg+-5deg b=32deg+-3deg c=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
a=64deg+-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=(90deg)

Information:

start by:a) disassemble governorb) remove fuel injection pumps 1. Remove cover (1) from the fuel injection pump housing. 2. Remove rack (2) from the fuel injection pump housing. 3. Remove the lifters (3) from the fuel injection pump housing. 4. Put the fuel injection pump housing on end on blocks and use tool (A) to remove snap ring (4) from the camshaft. 5. Use a soft hammer to push the camshaft toward the governor end of the fuel injection pump housing to loosen washer (5) on the camshaft. Remove washer (5). 6. Remove camshaft (6) from the fuel injection pump housing. 7. Remove bearings (7) from the drive end of the fuel injection pump housing. 8. Remove bearings (8) from the governor end of the fuel injection pump housing.Assemble Fuel Injection Pump Housing
Be sure all oil passages are clear and put clean oil on all parts before assembly. 1. Use tooling (A) to install bearing (2) in the governor end of the fuel injection pump housing with junction (joint) (3) toward the top of the fuel injection pump housing. Install the bearing so it is 0.25 0.20 mm (0.10 0.008 in.) below the surface of the housing.2. Use tooling (A) to install bearing (1) in the governor end of the fuel injection pump housing so it is 7.16 0.13 mm (0.282 0.005 in.) below the surface of the housing. 3. Use tooling (A) to install bearing (4) in the drive end of the fuel injection pump housing with the junction (joint) in the bearing toward the top of the fuel injection pump housing. Install the bearing so it is 1.00 0.25 mm (0.039 0.010 in.) below the surface of the housing. 4. Install plate (6) of tooling (C) on the drive end of the fuel injection pump housing to install the bearing for the rack. Use clean grease to hold the new rack bearing on driver (5) of tooling (C). Install the driver and bearing in plate (6) with the groove in the driver in alignment with the pin in the plate and use a hammer to push the bearing into position. The bearing will be installed to the correct depth when the shoulder of the driver is against plate (6).5. Remove tooling (C) from the fuel injection pump housing. The rack bearing must be installed so it is 0.25 0.25 mm (0.010 0.010 in.) below the surface of the housing. 6. Install camshaft (7) in the fuel injection pump housing.7. Put the fuel injection pump housing on end and put a block under the camshaft. 8. Put washer (9) over the end of the camshaft and use tooling (A) and a spacer (8) that has an inside diameter of 38.1 mm (1.5 in.) and a length of 31.75 mm (1.25 in.) to push the washer against its seat on the camshaft. Camshaft must have 0.285 0.235 mm (0.0112 0.0093 in.) end play when washer is pushed against