106871-8602 ZEXEL 9 400 618 285 BOSCH INJECTION-PUMP ASSEMBLY 9400618285 1068718602 220006971a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 285 9400618285

ZEXEL 106871-8602 1068718602

HINO 220006971A 220006971a

Service parts 106871-8602 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7850

3. GOVERNOR 105921-4322

4. SUPPLY PUMP 105237-4050

5. AUTOM. ADVANCE MECHANIS 105683-0000

6. COUPLING PLATE 105662-1220

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7161

11. Nozzle and Holder 23600-2240B

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105031-7230

14. NOZZLE

15. NOZZLE SET 105019-0010

Include in #1:

106871-8602 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 285 9400618285

ZEXEL 106871-8602 1068718602

HINO 220006971A 220006971a

Zexel num

Bosch num

Firm num

Name

106871-8602

9 400 618 285

220006971A HINO

INJECTION-PUMP ASSEMBLY
F17E 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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.8 4.74 4.8

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 12.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 136 132.5 139.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.7 6.7 12.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 136 134 138

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 135.5 129.5 141.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 138 132 144

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 137.5 131.5 143.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 145 155

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 710--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 660

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 0.7 0.4 1

Load 4/4

Timer adjustment_04

Pump speed r/min 880

Advance angle deg. 0.7 0.4 1

Load 3/4

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 5.25 4.95 5.55

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=G17
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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'
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aa=41mm
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a=35deg+-5deg b=(44deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=45mm
----------
a=(40deg)+-5deg b=8deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-2320) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (e) to the block (c). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V). (5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=900r/min Ra=R1(12.1)+0.2mm
----------