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


106671-3803 INJECTION-PUMP ASSEMBLY
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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

Test data 106671-3803
N:Pump speed R:Rack position (mm) (1)Damper spring setting: DL (2)RACK LIMIT
----------
DL=4.2-0.2mm
----------

Speed control lever angle

Test data 106671-3803
F:Full speed
----------

----------
a=7deg+-5deg

0000000901

Test data 106671-3803
F:Full load I:Idle (1)Use the hole at R = aa (2)Point E setting (3)At delivery
----------
aa=54mm
----------
a=14deg+-5deg b=39deg+-3deg c=39deg+-5deg

Stop lever angle

Test data 106671-3803
N:Pump normal S:Stop the pump.
----------

----------
a=39deg+-5deg b=48.5deg+-5deg

0000001501 Q ADJUSTMENT PIPING

Test data 106671-3803
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.
----------

----------

Timing setting

Test data 106671-3803
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)




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