106873-3402 ZEXEL 9 400 611 025 BOSCH INJECTION-PUMP ASSEMBLY 9400611025 1068733402 220008972a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 025 9400611025

ZEXEL 106873-3402 1068733402

HINO 220008972A 220008972a

Service parts 106873-3402 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5991

3. GOVERNOR 105489-5062

4. SUPPLY PUMP 105237-0080

5. AUTOM. ADVANCE MECHANIS 105683-0530

6. COUPLING PLATE 105664-2170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7793

11. Nozzle and Holder 23600-2741B

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/24.5{250}

13. NOZZLE-HOLDER 105030-3581

14. NOZZLE

15. NOZZLE SET 105019-0541

Include in #1:

106873-3402 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 025 9400611025

ZEXEL 106873-3402 1068733402

HINO 220008972A 220008972a

Zexel num

Bosch num

Firm num

Name

106873-3402
106873-3530

9 400 611 025

220008972A HINO

INJECTION-PUMP ASSEMBLY
F-2 * K 14CD INJECTION PUMP ASSY PE8P PE

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 131425-0020

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.2 4.14 4.2

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 139.5 137.5 141.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 137 134 140

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 8.35+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 132.5 124.5 140.5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 7.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 109.5 104.5 114.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 12 9 15

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_06

Adjusting point G

Rack position 9+-0.1

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 156.5 150.5 162.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 160 160 200

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 570--

Advance angle deg. 0 0 0

Load 0/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 520

Advance angle deg. 0.3

Load 0/5

Timer adjustment_03

Pump speed r/min (550)

Advance angle deg. 2 1.7 2.3

Load 0/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 2 1.7 2.3

Load 4/5

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 6.75 6.45 7.05

Load 5/5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (3)Stop lever's normal position setting: R2 (4)Excess fuel setting for starting: SXL (5)When air cylinder is operating. (6)Damper spring setting
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N1=300r/min R1=3.8mm N2=1100r/min Q1=3mm3/st R2=12+0.5mm SXL=9+-0.1mm
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Speed control lever angle

F:Full speed
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a=20.5deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Set point I (at air cylinder operation)
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aa=90mm
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a=35deg+-3deg b=(1deg)+-3deg c=10deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (set before setting excess fuel for starting) (2)Set the stopper bolt (apply red paint). (3)Use the pin at R = bb
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aa=12+0.5mm bb=37mm
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a=20deg+-5deg b=35deg+-5deg

0000001501 LEVER

1. Air cylinder adjustment (1)With the load lever in the idle position, temporarily set the distance between the load lever A and the air cylinder D at approximately L. (2)Set N1 and apply P1 to the air cylinder D. (3)Adjust set bolt (D) to obtain R1 at the same speed. (4)Lock using nut C. (5)Apply positive pressure several times. (6)Confirm that the load lever A returns to the idling position N2 at pressure P2. (7)Also at P1 confirm R1 (N1).
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L=5mm R1=3.8mm N1=275r/min N2=250r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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