106671-8494 ZEXEL 9 400 616 998 BOSCH INJECTION-PUMP ASSEMBLY 9400616998 1066718494 220008191a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 998 9400616998

ZEXEL 106671-8494 1066718494

HINO 220008191A 220008191a

Service parts 106671-8494 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7350

3. GOVERNOR 105488-1902

4. SUPPLY PUMP 105237-1600

5. AUTOM. ADVANCE MECHANIS 105681-5110

6. COUPLING PLATE 105663-0620

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5721

11. Nozzle and Holder 23600-1970B

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

13. NOZZLE-HOLDER 105031-5470

14. NOZZLE

105015-7020

15. NOZZLE SET

Include in #1:

106671-8494 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 998 9400616998

ZEXEL 106671-8494 1066718494

HINO 220008191A 220008191a

Zexel num

Bosch num

Firm num

Name

106671-8494

9 400 616 998

220008191A HINO

INJECTION-PUMP ASSEMBLY
K13C 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 134424-4420

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

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 4.4 4.34 4.4

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 9.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 204.1 202.1 206.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2+-0.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 208.1 202.1 214.1

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 200 195 205

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Rack limit *

Injection quantity adjustment_04

Adjusting point D

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 13 10 16

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_05

Adjusting point E

Rack position 6.15+-0. 1

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 128.9 126.9 130.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 143 143

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 6.15+-0. 1

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (9.2)

Boost pressure kPa 36 36 36

Boost pressure mmHg 270 270 270

Timer adjustment

Pump speed r/min 700--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 650

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3 2.7 3.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Damper spring setting (7)Set idle at delivery
----------
RT=0.8 TH=2.1mm BCL=(3.05)mm
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Speed control lever angle

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

----------
a=12.5deg+-5deg

0000000901

F:Full load I:Idle (1)Set point D (2)At delivery
----------

----------
a=25deg+-5deg b=46deg+-3deg c=48deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at rack = aa (apply red paint). (2)Rack position bb (3)Free (at delivery)
----------
aa=2.5-0.5mm bb=12mm
----------
a=40deg+-5deg b=30deg+-5deg c=(50deg)