106871-3602 ZEXEL 9 400 618 109 BOSCH INJECTION-PUMP ASSEMBLY 9400618109 1068713602 220004043b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 109 9400618109

ZEXEL 106871-3602 1068713602

HINO 220004043B 220004043b

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Service parts 106871-3602 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5650

3. GOVERNOR 105488-8911

4. SUPPLY PUMP 105237-1410

5. AUTOM. ADVANCE MECHANIS 105681-0022

6. COUPLING PLATE 105662-0790

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7040

11. Nozzle and Holder 23600-1602

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

13. NOZZLE-HOLDER 105031-7140

14. NOZZLE

105015-4700

15. NOZZLE SET

Include in #1:

106871-3602 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 109 9400618109

ZEXEL 106871-3602 1068713602

HINO 220004043B 220004043b

Zexel num

Bosch num

Firm num

Name

106871-3602

9 400 618 109

220004043B HINO

INJECTION-PUMP ASSEMBLY
EF750 * 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 A

Rack position 7.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 125.7 123.7 127.7

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 144.3 138.3 150.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 139.1 136.1 142.1

Fixing the lever *

Injection quantity adjustment_04

Adjusting point -

Rack position 5.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_05

Adjusting point E

Rack position 7.7

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 126 116 136

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 150 170

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position 7.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 126.4 123.4 129.4

Fixing the lever *

Timer adjustment

Pump speed r/min (875)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1075

Advance angle deg. 4.75 4.45 5.05

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target shim dimension: TH (2)Beginning of damper spring operation: DL (3)Excess fuel setting for starting: SXL
----------
TH=2.2mm DL=3.8-0.5mm SXL=8.3+0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=22deg+-5deg

0000000901

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

----------
a=36deg+-3deg b=39deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=15deg+-5deg b=64deg+-5deg

Timing setting

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

----------
a=(80deg)

Information:

Specifications
Illustration 42 g03135400
Table 13
Fuel Injection Pump Camshaft
Model Dimension A Dimension B Dimension C Dimension D Dimension E
3064
3066 40.72 0.25 mm (1.603 0.010 inch) 20.003 0.005 mm (0.7875 0.0002 inch) 11.13 0.25 mm (0.438 0.010 inch) 16.955 0.005 mm (0.6675 0.0002 inch) 16.26 0.25 mm (0.640 0.010 inch) Note: All sprayed edges should be rounded with a 0.795 mm (0.0313 inch) radius.Storage Procedures
Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 43.When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 44.Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 43 g06278538
Example of protection for a component that is stored for a shorter term
Illustration 44 g06278539
Example of protection for a component that is stored for a longer period