107691-3541 ZEXEL 9 400 612 717 BOSCH INJECTION-PUMP ASSEMBLY 9400612717 1076913541 220402232a


107691-3541 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 717 9400612717
ZEXEL 107691-3541 1076913541
HINO 220402232A 220402232a

Service parts 107691-3541 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-0640
3. GOVERNOR 105962-0181
4. SUPPLY PUMP 105237-6480
5. AUTOM. ADVANCE MECHANIS 105681-5872
6. COUPLING PLATE 105664-2480
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105101-8384
11. Nozzle and Holder 23600-3233B
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-3700
14. NOZZLE
15. NOZZLE SET 105019-2132

Include in #1:

107691-3541 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 717 9400612717
ZEXEL 107691-3541 1076913541
HINO 220402232A 220402232a


Zexel num
Bosch num
Firm num
Name
107691-3541 
107691-3542 
9 400 612 717 
220402232A  HINO
INJECTION-PUMP ASSEMBLY
J08C * K 14CG 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   105780-8330
Nozzle   105780-0130
Nozzle holder   105780-2250
Opening pressure MPa   16.7
Opening pressure kgf/cm2   170
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   134424-4120
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   225 225 225
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
RED4 control unit part number   407915-0 590
RED4 rack sensor specifications mm   19
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
Rack position   (10.3)
PWM %   46.3
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   83.5 82.5 84.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Injection quantity adjustment_02
Rack position   (6.6)
PWM %   25.2+-2. 8
Pump speed r/min   315 315 315
Each cylinder's injection qty mm3/st.   13 12 14
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
 
Governor adjustment
Pump speed r/min   1210--
Advance angle deg.   0 0 0
Load   2/5
Remarks
Start
 
Governor adjustment_02
Pump speed r/min   1160
Advance angle deg.   0.3
Load   2/5
Governor adjustment_03
Pump speed r/min   1360
Advance angle deg.   3.3 3 3.6
Load   5/5
Remarks
Finish
 
0000001201
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:

Speed control lever angle

Test data 107691-3541
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=18.5deg+-5deg b=37deg+-5deg

0000000901

Test data 107691-3541
(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=(20deg)

Stop lever angle

Test data 107691-3541
(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.
----------

----------

0000001301

Test data 107691-3541
A : Stopper pin B: Connector
----------

----------

0000001401

Test data 107691-3541
C:Shim
----------

----------

0000001501

Test data 107691-3541
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.
----------

----------

0000001701

Test data 107691-3541
(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
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