106671-3970 ZEXEL 9 400 616 788 BOSCH INJECTION-PUMP ASSEMBLY 9400616788 1066713970 220202621a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 788 9400616788

ZEXEL 106671-3970 1066713970

HINO 220202621A 220202621a

Service parts 106671-3970 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-7581

3. GOVERNOR 105407-3290

4. SUPPLY PUMP 105217-1301

5. AUTOM. ADVANCE MECHANIS 105636-1280

6. COUPLING PLATE 105662-0910

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5273

11. Nozzle and Holder 236001561C

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105031-4451

14. NOZZLE 105015-4920

15. NOZZLE SET

Include in #1:

106671-3970 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 788 9400616788

ZEXEL 106671-3970 1066713970

HINO 220202621A 220202621a

Zexel num

Bosch num

Firm num

Name

106671-3970

9 400 616 788

220202621A HINO

INJECTION-PUMP ASSEMBLY
EP100T * 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) 134424-2020

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) 134424-2120

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 4.4 4.5

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 7.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 101 99 103

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_02

Adjusting point B

Rack position 5.3+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 10 7 13

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_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 135 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 6.5

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position 7.5

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Timer adjustment

Pump speed r/min 975--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 925

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
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K=15 BCL=1+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=12deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=5deg+-5deg b=45deg+-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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