106671-3803 ZEXEL 9 400 616 782 BOSCH INJECTION-PUMP ASSEMBLY 9400616782 1066713803 220004513a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 782 9400616782

ZEXEL 106671-3803 1066713803

HINO 220004513A 220004513a

Cross reference number

BOSCH 9 400 616 782 9400616782

ZEXEL 106671-3803 1066713803

HINO 220004513A 220004513a

Zexel num

Bosch num

Firm num

Name

106671-3803
106671-3804

9 400 616 782

220004513A HINO

INJECTION-PUMP ASSEMBLY
EP100 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 (drive side) 134424-1420

Overflow valve opening pressure (drive side) kPa 162 147 177

Overflow valve opening pressure (drive side) kgf/cm2 1.65 1.5 1.8

Overflow valve (governor side) 134424-1520

Overflow valve opening pressure (governor side) kPa 162 147 177

Overflow valve opening pressure (governor side) 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

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 4.5 4.44 4.5

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 7.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 132.7 130.7 134.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point B

Rack position 7.1+-0.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 111.4 107.4 115.4

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_03

Adjusting point C

Rack position 7.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 133.7 130.7 136.7

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_04

Adjusting point D

Rack position 8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 135.8 132.8 138.8

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_05

Adjusting point E

Rack position 4.7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.3 9.3 15.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point F

Rack position 7.7+-0.5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 89 89

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point G

Rack position -

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 156.3 156.3 166.3

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_08

Adjusting point H

Rack position 6.1+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 67.3 65.3 69.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position (6.1)

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 7.9

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Timer adjustment

Pump speed r/min 700+100

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 2.5 2.2 2.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)RACK LIMIT
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DL=4.2-0.2mm
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Speed control lever angle

F:Full speed
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a=7deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Point E setting (3)At delivery
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aa=54mm
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a=14deg+-5deg b=39deg+-3deg c=39deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=39deg+-5deg b=48.5deg+-5deg

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A Adjust screw A so that the timer advance angle determined in (B) can be obtained. Fuel inlet C Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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