106873-3581 ZEXEL 9 400 618 444 BOSCH INJECTION-PUMP ASSEMBLY 9400618444 1068733581 220801800a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 444 9400618444

ZEXEL 106873-3581 1068733581

HINO 220801800A 220801800a

Cross reference number

BOSCH 9 400 618 444 9400618444

ZEXEL 106873-3581 1068733581

HINO 220801800A 220801800a

Zexel num

Bosch num

Firm num

Name

106873-3581

9 400 618 444

220801800A HINO

INJECTION-PUMP ASSEMBLY
YJ41 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 131425-0020

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 4.2 4.14 4.2

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 8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 143.5 141.5 145.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 140 137 143

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 8.05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136.5 132.5 140.5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 7.6

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 122.5 117.5 127.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12 11 13

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_06

Adjusting point G

Rack position 8.35+-0. 1

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 149.5 143.5 155.5

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 570--

Advance angle deg. 0 0 0

Load 0/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 520

Advance angle deg. 0.3

Load 0/5

Timer adjustment_03

Pump speed r/min (550)

Advance angle deg. 2 1.7 2.3

Load 0/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 2 1.7 2.3

Load 4/5

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 6.75 6.45 7.05

Load 5/5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (3)Excess fuel setting for starting: SXL (4)Damper spring setting (5)Variable speed specification: idling adjustment (6)Main spring setting
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N1=300r/min R1=3.4mm N2=1100r/min Q1=3mm3/st SXL=8.35+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Stopper bolt setting (4)Stopper bolt setting
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aa=1290r/min bb=700r/min
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a=14.5deg+-5deg b=(12deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=42mm
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a=39deg+-5deg b=39.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (set before setting excess fuel for starting) (2)Set the stopper bolt (apply red paint). (3)Use the hole at R = bb
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aa=12+0.5mm bb=37mm
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a=17.5deg+-5deg b=35deg+-5deg

0000001201

(1)Minimum - maximum speed specification (2)Variable speed specification
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a=(14deg)+-5deg b=(30deg)

0000001501 LEVER

2-stage changeover lever adjustment (A) Speed lever (B) Load lever (C) 2-stage changeover lever (D) Link (E) Bolt (G) Variable speed specifications (H) Minimum maximum speed specifications F:Full speed I:Idle 1. Minimum-maximum speed specification adjustment (when running) (1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper. (2)In this condition, the load lever is held in the idle position. (3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L. (4)Lock using the nut. 2. Variable speed specification adjustment (at operation) (1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.) (2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
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L=1~2mm
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