106672-3282 ZEXEL 9 400 617 078 BOSCH INJECTION-PUMP ASSEMBLY 9400617078 1066723282 220005222a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 617 078 9400617078

ZEXEL 106672-3282 1066723282

HINO 220005222A 220005222a

Cross reference number

BOSCH 9 400 617 078 9400617078

ZEXEL 106672-3282 1066723282

HINO 220005222A 220005222a

Zexel num

Bosch num

Firm num

Name

106672-3282

9 400 617 078

220005222A HINO

INJECTION-PUMP ASSEMBLY
EP1 K

106672-3282

9 400 617 078

S220005222A HINO

INJECTION-PUMP ASSEMBLY
EP1 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 (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) 134424-1720

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 8.4

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 146.7 144.7 148.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point C

Rack position 8.2

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 141.1 135.1 147.1

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_03

Adjusting point D

Rack position 7.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 131 126 136

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_04

Adjusting point E

Rack position 9.8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 180.6 177.6 183.6

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_05

Adjusting point G

Rack position 6.3

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 72.9 70.9 74.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position 4.6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.4 5.4 11.4

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 6.3

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 8.4

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Set idle at delivery (3)Damper spring setting: DL (4)Rack difference between N = N1 and N = N2
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DL=4.4-0.2mm N1=1075r/min N2=700r/min
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Speed control lever angle

F:Full speed
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a=6deg+-5deg

0000000901

F:Full load I:Idle (1)Set point I (2)At delivery
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a=25deg+-5deg b=39deg+-3deg c=41.5deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Free (at delivery) (4)Set the stopper bolt (apply red paint).
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aa=12mm bb=2.5-0.5mm
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a=40deg+-5deg b=30deg+-5deg c=(50deg)

0000001501 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
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N1=700r/min Ra=8.4mm VR=1.7+-0.01V
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0000001601 Q ADJUSTMENT PIPING

Tester fuel pipe A (B) branch piping Fuel inlet C (D) Overflow valve 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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