106991-3002 ZEXEL F 01G 09U 0CW BOSCH INJECTION-PUMP ASSEMBLY f01g09u0cw 1069913002 220008022a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 0CW f01g09u0cw

ZEXEL 106991-3002 1069913002

HINO 220008022A 220008022a

Service parts 106991-3002 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106099-5010

3. GOVERNOR 105489-4000

4. SUPPLY PUMP 105237-4470

5. AUTOM. ADVANCE MECHANIS 105683-0300

6. COUPLING PLATE 105664-0851

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7455

11. Nozzle and Holder 23600-2480E

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

13. NOZZLE-HOLDER 105030-3474

14. NOZZLE

15. NOZZLE SET 105019-0171

Include in #1:

106991-3002 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0CW f01g09u0cw

ZEXEL 106991-3002 1069913002

HINO 220008022A 220008022a

Zexel num

Bosch num

Firm num

Name

106991-3002
106991-3003

F 01G 09U 0CW

220008022A HINO

INJECTION-PUMP ASSEMBLY
V-1 * 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 134424-1020

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 1-10-9-4 -3-6-5-8 -7-2

Pre-stroke mm 4.5 4.44 4.5

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-10 deg. 27 26.75 27.25

Difference between angles 2
Cal 1-9 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-4 deg. 99 98.75 99.25

Difference between angles 4
Cal 1-3 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-6 deg. 171 170.75 171.25

Difference between angles 6
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-8 deg. 243 242.75 243.25

Difference between angles 8
Cal 1-7 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 9.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 152 150 154

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 146 143 149

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.3+-0.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 141.5 138.5 144.5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 8.6

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 124 121 127

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position 4.3+-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 *

Injection quantity adjustment_06

Adjusting point F

Rack position 9.75+-0. 1

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 166.5 163.5 169.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_07

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 180 180 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 620

Advance angle deg. 1.5 1.2 1.8

Load 4/4

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 1.5 1.2 1.8

Load 3/4

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 5.75 5.45 6.05

Load 4/4

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)Excess fuel setting for starting: SXL (5)Damper spring setting (6)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2).
----------
RT=1 TH=2.5mm SXL=9.75+-0.1mm N1=300r/min R1=4.3mm N2=1100r/min Q1=3mm/st
----------

Speed control lever angle

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

----------
a=20.5deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole to the left of R = aa (2)Stopper bolt setting
----------
aa=56mm
----------
a=30.5deg+-3deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa; set before governor adjustment. (2)Set the stopper bolt (apply red paint). (3)Use the hole at R = bb
----------
aa=16.5+-0.5mm bb=25mm
----------
a=40deg+-5deg b=50deg+-5deg