106871-8701 ZEXEL 9 400 618 294 BOSCH INJECTION-PUMP ASSEMBLY 9400618294 1068718701 220007021b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 294 9400618294

ZEXEL 106871-8701 1068718701

HINO 220007021B 220007021b

Service parts 106871-8701 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7910

3. GOVERNOR 105489-2651

4. SUPPLY PUMP 105237-4050

5. AUTOM. ADVANCE MECHANIS 105683-0010

6. COUPLING PLATE 105664-0461

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7183

11. Nozzle and Holder 236002252A

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/24.5(250)

13. NOZZLE-HOLDER 105030-3482

14. NOZZLE

105015-8710

15. NOZZLE SET

Include in #1:

106871-8701 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 294 9400618294

ZEXEL 106871-8701 1068718701

HINO 220007021B 220007021b

Zexel num

Bosch num

Firm num

Name

106871-8701

9 400 618 294

220007021B HINO

INJECTION-PUMP ASSEMBLY
F20C 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 134424-1020

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 4.5 4.44 4.5

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 A

Rack position 9.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 154.4 152.4 156.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 155.5 152.5 158.5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.25

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 152.7 149.7 155.7

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 9.25+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 143.5 139.5 147.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position 8.45

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 123.9 120.9 126.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point F

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.1 9.1 15.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_07

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 185 145 225

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 660

Advance angle deg. 0.3

Load 1/4

Timer adjustment_02

Pump speed r/min 800--

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_03

Pump speed r/min 880+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_04

Pump speed r/min 1100-50

Advance angle deg. 4.75 4.45 5.05

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting
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SXL=9.75+-0.1mm
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Speed control lever angle

F:Full speed
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a=15.5deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=39mm
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a=39deg+-5deg b=44.5deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Use the hole above R = cc (4)Free (at delivery) (5)Set the stopper bolt (apply red paint).
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aa=11.8mm bb=2-0.5mm cc=28mm
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a=(13deg) b=46.5deg+-5deg c=29deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=900r/min Ra=9.25mm
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