107691-3740 ZEXEL 9 400 619 902 BOSCH INJECTION-PUMP ASSEMBLY 9400619902 1076913740 220402530a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 902 9400619902

ZEXEL 107691-3740 1076913740

HINO 220402530A 220402530a

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Buy INJECTION-PUMP ASSEMBLY 107691-3740 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-3740 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0760

3. GOVERNOR 105933-1750

4. SUPPLY PUMP 105237-6480

5. AUTOM. ADVANCE MECHANIS 105681-6120

6. COUPLING PLATE 105664-2630

7. COUPLING PLATE

8. _ 159645-4520

9. _

10. NOZZLE AND HOLDER ASSY 105101-8422

11. Nozzle and Holder

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:

107691-3740 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 902 9400619902

ZEXEL 107691-3740 1076913740

HINO 220402530A 220402530a

Zexel num

Bosch num

Firm num

Name

107691-3740

9 400 619 902

220402530A HINO

INJECTION-PUMP ASSEMBLY
J08C-TI K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

107691-3740

9 400 619 902

S220402530 HINO

INJECTION-PUMP ASSEMBLY
J08C-TI 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 12.9

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123 120 126

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 8.2+-0.5

Pump speed r/min 440 440 440

Each cylinder's injection qty mm3/st. 13.5 12.15 14.85

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(12.9)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123 121 125

Basic *

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

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. 135.5 129.5 141.5

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

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 R2-0.9

Boost pressure kPa 24.7 23.4 26

Boost pressure mmHg 185 175 195

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1)

Boost pressure kPa 58.7 58.7 58.7

Boost pressure mmHg 440 440 440

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 -0.3 0

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Measure the actual speed, stop

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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at the full setting. (4)Stop lever's normal position setting: RA (5)Boost compensator stroke: BCL
----------
T1=AF50 Ra=R1+2.15mm RA=(18)mm BCL=0.9+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=44mm
----------
a=8.5deg+-5deg b=(34deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (apply red paint) (3)Set the stopper bolt at rack position = dd (apply red paint).
----------
aa=40mm bb=0r/min cc=1.5+-0.1mm dd=(18)mm
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a=15deg+-5deg b=35deg+-5deg

0000001301

(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
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a=(30deg)

0000001401

(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.
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0000001701

A : Stopper pin B: Connector
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0000001801

C:Shim
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0000001901

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.
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0000002201 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.9)+2.15mm N1=1250r/min V1=3+-0.01V
----------

Information:

5. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing, and fasten a hoist to it.6. Install tooling (A) on the BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at removal. This prevents damage to the rotor rings and seals.7. Remove bolts (6) that hold BrakeSaver housing (7) to the flywheel housing.8. Use bolts (4) as forcing screws, and tighten the bolts evenly to remove BrakeSaver housing (7) from the flywheel housing. The weight is 86 kg (190 lb.).Install BrakeSaver
1. Install tooling (A) on the BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at installation. This prevents damage to the rotor rings and seals.2. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing, and fasten a hoist to it.3. Install two 5/8"-18 guide bolts (3) in the crankshaft as shown. Make sure dowel (2) is in alignment with the dowel hole in the rotor assembly, and put BrakeSaver housing (1) in position in the flywheel housing.4. Install the three bolts that hold the BrakeSaver housing to the flywheel housing. Remove tooling (A) and guide pins (3). 5. Connect the oil line to fitting (6).6. Inspect the O-ring seals for damage, and make replacements if needed. Install O-ring seals (4) and (5). Put clean engine oil on the O-ring seals.7. Install manifold (7) into the BrakeSaver control valve, and install the four bolts that hold the manifold to the BrakeSaver housing. 8. Connect BrakeSaver lubrication oil line (8) to the fitting in the BrakeSaver housing.END BY:a. install flywheel (BrakeSaver)Disassemble BrakeSaver
START BY:a. remove BrakeSaver1. Remove tooling (A) from the BrakeSaver housing and rotor. Tooling (A) prevents damage to the rotor seals and rings during removal of the BrakeSaver housing. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Put alignment marks on stator (3) and housing (4) for assembly purposes. Remove bolts (5) and the stator. 4. Turn the stator over, and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip-type seal (8) from the sleeve. 6. Remove O-ring seal (11) and the six smaller O-ring seals from the oil holes on the housing.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over, and remove sleeve assembly (17). Remove the lip-type seal and O-ring seal (16) from the sleeve.Assemble BrakeSaver
1. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install O-ring seal (2) on sleeve (1).3. Install the sleeve in the BrakeSaver housing. Make an alignment of the notch (3) on the sleeve with the notch in the housing, and install the dowel.
Make certain there is clearance behind the spiral ring when it is