106671-8031 ZEXEL 9 400 616 968 BOSCH INJECTION-PUMP ASSEMBLY 9400616968 1066718031 220005600b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 968 9400616968

ZEXEL 106671-8031 1066718031

HINO 220005600B 220005600b

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Cross reference number

BOSCH 9 400 616 968 9400616968

ZEXEL 106671-8031 1066718031

HINO 220005600B 220005600b

Zexel num

Bosch num

Firm num

Name

106671-8031

9 400 616 968

220005600B HINO

INJECTION-PUMP ASSEMBLY
EK200 * K 14CA PE6P,6PD 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure 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)
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 4.8 4.74 4.8

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 7.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 153 150 156

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 151 149 153

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.3

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 159 156 162

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 4+-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_05

Adjusting point E

Rack position 8.6+-0.5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Injection quantity adjustment_06

Adjusting point F

Rack position 7.2

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 134.7 129.7 139.7

Fixing the lever *

Timer adjustment

Pump speed r/min 865+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1075

Advance angle deg. 4.5 4.2 4.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT: RAL (2)Damper spring setting: DL
----------
RAL=(8.6)mm DL=3.3-0.2mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg

0000000901

F:Full load I:Idle
----------

----------
a=17deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=64deg+-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=300+25r/min Ra=4mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(0deg)

Information:

Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.If the crankshaft, gear case and/or crank gear are replaced, it is necessary to perform the injection timing correction procedure. The following steps show how to calculate/determine the new injection timing by measuring angular deviation between the crankshaft TDC and Crank Position sensor detected TDC.Note: Once complete the engine ecm must be reprogrammed with the new injection timing value. Follow all Steps below.Procedure
Illustration 1 g06220080
(1) TC Mark (Flywheel Housing)
(2) TC Mark (Flywheel)
Remove valve cover, injector, and rocker arm. Bring the piston of cylinder 4 to TDC.
Illustration 2 g06220082
(3) Dial Gauge
(4) Valve
(5) O-ring
Remove the #4 exhaust valve bridge arm and valve spring. Insert a small O-ring (5) so the valve (4) does not fall into the cylinder.
Set the dial gauge (3) on the tip of the valve (4).
Illustration 3 g06220083
(6) Tri-sqaure
(7) Flywheel Housing
(8) Flywheel
Illustration 4 g06220087
(7) Flywheel Housing
(8) Flywheel
(9) Reference Line
Turn the flywheel counterclockwise and measure the position where the tip of the valve is highest.
Stop the flywheel at the position where the tip of the valve is the highest. Put a tri-sqaure (6) on the flywheel housing (7) and the flywheel (8) and draw a reference line (9).Do not drop the valve (4) into the cylinder. When measuring the highest position of the tip of the valve do not rotate the flywheel clockwise. If you go past the highest point of the valve, back up the flywheel slightly and measure the highest point of the valve. The reference line (9) indicates the TDC of the crankshaft.
Illustration 5 g06220092
(10) Tester
(11) Crankshaft Position Sensor
Illustration 6 g06220095
(11) Crankshaft Position Sensor
(12) Ground Terminal
(13) Output Terminal
Connect the engine harness and the main switch. Connect battery.Attach the tester (10) to the output terminal (13) and the ground terminal (12) of the crankshaft position sensor (11). Turn the main switch "ON". Turn the flywheel and make sure that the voltage of the crankshaft position sensor goes from 0→ 5 V or 5 → 0 V.
Illustration 7 g06220100
(14) Pulsar Gear
(15) 14th Tooth
(16) Missing Teeth
Rotate the flywheel and align the crankshaft position sensor to the part of the pulsar gear (14) that is missing teeth (16). The 14th tooth (15) from the missing teeth is the standard. Slowly turn the flywheel counterclockwise and stop the flywheel at the point where the needle of the tester changes momentarily from 0→ 5 V, the 14th tooth. That point is where the crankshaft position sensor detects TDC.
Illustration 8 g06220101
(17) Crankshaft TDC
(18) Detection Point of Crankshaft Position Sensor TDC
Illustration 9 g06220104
(19) Interval
Set the tri-square (6) on the reference line (9) on the flywheel housing side and mark the detection point of the crankshaft position sensor TDC (18) on the flywheel.
Measure the interval (19) between the crankshaft TDC (17) and the detection point of the crankshaft position sensor TDC (18).
Calculation of the fuel injection timing correction 1 mm (0.039 inch): 0.342°.Corrected angle = 0.342° X actual interval.
Overwrite the injection timing correction value on the engine ecm registration website refer to REHS9707, "Registering