106691-3042 ZEXEL 9 400 617 783 BOSCH INJECTION-PUMP ASSEMBLY 9400617783 1066913042 220201572a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 783 9400617783

ZEXEL 106691-3042 1066913042

HINO 220201572A 220201572a

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Cross reference number

BOSCH 9 400 617 783 9400617783

ZEXEL 106691-3042 1066913042

HINO 220201572A 220201572a

Zexel num

Bosch num

Firm num

Name

106691-3042

9 400 617 783

220201572A HINO

INJECTION-PUMP ASSEMBLY
ER100 * 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 134424-0920

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.45 3.4 3.5

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 95 93 97

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 10.5 7.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 0.9

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm.
----------
K=10
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=8deg+-5deg b=27deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=5.5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(40deg)

Information:

Test Procedure
System Operation
An energized input closes the N.O. contacts. An energized input opens the N.C. contacts. Digital modules are used to determine whether a circuit is ON/OFF. A number of modules are available. The most common modules have sixteen channels.
Illustration 1 g00563503
Diagram of the programmable logic controller
Illustration 2 g00563591
Schematic of the discrete inputFunctional Test
Check the electrical connectors and check the wiring.
Bodily contact with electrical potential can cause bodily injury or death.To avoid the possibility of injury or death, ensure that the main power supply has been disconnected before performing any maintenance or removing any modules.
Disconnect the power supply.
Check the electrical connectors and check the wiring for damage or bad connections.
Verify that all modules are properly seated.
Verify the status of the LED on the SLC 5/04.The results of the preceding procedure are in the following list:
All of the components are fully installed. All of the components are free of corrosion. All of the components are free of damage. All of the modules are properly seated. Proceed to 2.
The components are not fully installed. The components are not free of corrosion. The components are damaged. All of the modules are not properly seated. Repair the component. Verify that the repair resolves the problem. STOP.
Verify the value of the channel.
Get on-line with the PLC.
Locate the software address for the channel.The results of the preceding procedure are in the following list:
The channel has a software address. Proceed to 3.
The channel does not have a software address. Replace the module. Verify that the repair resolves the problem. Refer to Maintenance Procedure, "Input Module and Output Module - Replace". Stop.
Apply the rated voltage.
Apply the rated voltage to the channel.
Verify that the address changed from zero to one.Note: The LED will illuminate when the rated voltage is applied to the channel.The results of the preceding procedure are in the following list:
The software address value changes. The module is functioning normally. Stop.
The software address value does not change. the module is not functioning normally. Replace the module. Verify that the repair resolves the problem. Refer to Maintenance Procedure, "Input Module and Output Module - Replace". Stop.