107691-3500 ZEXEL 9 400 612 387 BOSCH INJECTION-PUMP ASSEMBLY 9400612387 1076913500 220402160a


107691-3500 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 387 9400612387
ZEXEL 107691-3500 1076913500
HINO 220402160A 220402160a

Service parts 107691-3500 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-0340
3. GOVERNOR 105933-1500
4. SUPPLY PUMP 105237-6260
5. AUTOM. ADVANCE MECHANIS 105681-5590
6. COUPLING PLATE 105664-2460
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105101-8422
11. Nozzle and Holder 23600-3222B
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}
13. NOZZLE-HOLDER 105030-3700
14. NOZZLE
15. NOZZLE SET 105019-2170

Include in #1:

107691-3500 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 387 9400612387
ZEXEL 107691-3500 1076913500
HINO 220402160A 220402160a


Zexel num
Bosch num
Firm num
Name
107691-3500 
9 400 612 387 
220402160A  HINO
INJECTION-PUMP ASSEMBLY
J08C-TT K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS
107691-3500 
9 400 612 387 
S220402160A  HINO
INJECTION-PUMP ASSEMBLY
J08C-TT A K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   131425-0920
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   17
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   5.1 5.07 5.13
Beginning of injection position
Governor 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   -
Rack position   12.4
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   117.5 114.5 120.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8+-0.5
Pump speed r/min   440 440 440
Each cylinder's injection qty mm3/st.   13.5 12.5 14.5
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5+-0.03
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.4)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   117.5 115.5 119.5
Basic   *
Fixing the lever   *
Boost pressure kPa   54 54
Boost pressure mmHg   405 405
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+2.15
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   133 127 139
Fixing the lever   *
Boost pressure kPa   54 54
Boost pressure mmHg   405 405
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-1.5
Boost pressure kPa   21.3 20 22.6
Boost pressure mmHg   160 150 170
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-1)
Boost pressure kPa   40.7 40.7 40.7
Boost pressure mmHg   305 305 305
Timer adjustment
Pump speed r/min   0
Advance angle deg.   0 0 0
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   0 0 0
Remarks
Measure speed (beginning of operation).
 
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   -1.5 -1.8 -1.2
Remarks
Speed, measure actual advance, end of effect
 
0000001601
CU407980-224*   *
Actuator retarding type   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2 1.95 2.05
Output voltage V   2.83 2.82 2.84
Adjustment   *
_02
CU407980-224*   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.1 5.07 5.13
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_03
CU407980-224*   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 107691-3500
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Stop lever's normal position setting: R1 (4)Boost compensator stroke: BCL
----------
T1=AH03 R1=(18)mm BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 107691-3500
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=8deg+-5deg b=36.5deg+-3deg

Stop lever angle

Test data 107691-3500
N:Pump normal S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Speed = bb, rack position = cc (3)Use the hole above R = dd
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
a=15deg+-5deg b=35deg+-5deg

0000001301

Test data 107691-3500
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.1+-0.03mm
----------
a=(80deg)

0000001401

Test data 107691-3500
(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

Test data 107691-3500
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-3500
C:Shim
----------

----------

0000001901

Test data 107691-3500
A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 RACK SENSOR

Test data 107691-3500
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1250r/min Ra=R1(12.4)+2.15mm
----------

0000002301 ACS

Test data 107691-3500
(P) Absolute pressure (R) Rack position (mm) 1. Adjustment of the aneroid compensator (1)Screw in the aneroid compensator body and attach the pushrod to the compensator lever so that the performance in the above graph can be obtained. The control lever must be at the full set position N = N1.
----------
N1=1250r/min
----------
Ra=R3(R1+2.15)mm Rb=R3-0.75mm Rc=(R3-0.9)mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) P3=65.7+-1.3kPa(493+-10mmHg) Q1=133+-6mm3/st Q2=121.5+-10mm3/st Q3=119.5+-10mm3/st




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Hino 

107691-3500  
9 400 612 387 
220402160A 
INJECTION-PUMP ASSEMBLY
J08C-TT
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S220402160A 
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9 400 613 281 
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9 400 618 975 
220402451B 
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