108622-3090 ZEXEL 9 400 612 893 BOSCH INJECTION-PUMP ASSEMBLY 9400612893 1086223090 220007552a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 893 9400612893

ZEXEL 108622-3090 1086223090

HINO 220007552A 220007552a

Service parts 108622-3090 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-0100

3. GOVERNOR 105488-1870

4. SUPPLY PUMP 105237-4410

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0680

7. COUPLING PLATE 156638-0320

8. _ 159590-6620

9. _

10. NOZZLE AND HOLDER ASSY 105101-7342

11. Nozzle and Holder 23600-2391B

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/27.5{280}

13. NOZZLE-HOLDER 105030-3330

14. NOZZLE

15. NOZZLE SET 105019-0130

Include in #1:

108622-3090 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 893 9400612893

ZEXEL 108622-3090 1086223090

HINO 220007552A 220007552a

Zexel num

Bosch num

Firm num

Name

108622-3090
108622-3091

9 400 612 893

220007552A HINO

INJECTION-PUMP ASSEMBLY
P-4 A * 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 134424-1520

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 21

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 185.7 183.7 187.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 160.9 157.9 163.9

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_03

Adjusting point C

Rack position 8.3+-0.1

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 125.9 122.9 128.9

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_04

Adjusting point D

Rack position 10.6+-0. 1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 192 182 202

Fixing the lever *

Boost pressure kPa 62.7 62.7

Boost pressure mmHg 470 470

Rack limit *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_05

Adjusting point E

Rack position 4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.5 9.5 15.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 7.9

Boost pressure kPa 22 20 22

Boost pressure mmHg 165 150 165

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position 10.2

Boost pressure kPa 49.3 49.3 49.3

Boost pressure mmHg 370 370 370

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 5 4.5 5.5

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 4 3.95 4.05

Output voltage V 2.62 2.61 2.63

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 3.4

Output voltage V 3 2.98 3

Confirmation *

_06

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Stop lever setting: R1 (3)RACK LIMIT: RAL (4)Boost compensator stroke: BCL (5)Damper spring setting
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R1=12.4+0.2mm RAL=10.6+-0.1mm BCL=2.3+-0.1mm
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Speed control lever angle

F:Full speed
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a=11deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=50mm
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a=25deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set stopper screw so that rack position = bb (after setting apply red paint). (3)Set before governor adjustment.
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aa=33mm bb=12.4+0.2mm
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a=30deg+-5deg b=42deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(40deg)

0000001901

(A): Pre-stroke actuator (B): Stamp housings A and B at the same time. (C): Stamping range 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-0720) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (E) to the block (C). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
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L=33.5+-0.1mm N1=550r/min Ra=10.2mm
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