106871-8182 ZEXEL 9 400 618 259 BOSCH INJECTION-PUMP ASSEMBLY 9400618259 1068718182 220005864a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 259 9400618259

ZEXEL 106871-8182 1068718182

HINO 220005864A 220005864a

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Cross reference number

BOSCH 9 400 618 259 9400618259

ZEXEL 106871-8182 1068718182

HINO 220005864A 220005864a

Zexel num

Bosch num

Firm num

Name

106871-8182
106871-8183

9 400 618 259

220005864A HINO

INJECTION-PUMP ASSEMBLY
F17C 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 9.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 140.2 138.2 142.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136.8 130.8 142.8

Max. variation between cylinders % 0 -14 14

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 138.4 135.4 141.4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 9.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 143.8 140.8 146.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position 9.4

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 119.3 116.3 122.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point F

Rack position 4.2+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 9.1 6.1 12.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 900

Advance angle deg. 1.7 1.4 2

Load 3/4

Timer adjustment_02

Pump speed r/min 1060

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)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL (after setting the idle spring)
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RT=0.8 TH=2.6mm SXL=11+-0.1mm DL=4.8-0.2mm
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Speed control lever angle

F:Full speed
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a=14deg+-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=46deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Rack position = aa (3)Rack position bb (4)Set the stopper bolt (apply red paint).
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aa=12mm bb=3mm
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a=26deg+-5deg b=5deg+-5deg c=(28deg)

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=1070r/min Ra=10.1mm
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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:

(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Depth of bore in head for valve seat insert ... .442 .002 in.(11.23 0.05 mm)(3) Diameter of valve seat insert ... 1.9120 .0005 in.(48.565 0.013 mm) Bore in head for valve seat insert ... 1.9090 .0005 in.(44.489 0.013 mm)(4) Maximum permissible width of the face of the valve seat insert ... .105 in.(2.67 mm)(5) Angle of the face of the valve seat insert ... 451/4° 1/2°(6) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .085 in.(2.16 mm)Minimum permissible (valve closed) ... .050 in.(1.27 mm)(7) Outside diameter of the face of the valve seat insert ... 1.735 .005 in.(44.07 0.13 mm) Maximum permissible ... 1.760 in.(44.70 mm)(8) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°Intake Valve (without valve seat insert)
(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Maximum permissible width of the face of the valve seat ... .120 in.(3.05 mm)(3) Angle of the face of the valve seat ... 301/4° 1/2°(4) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)Minimum permissible (valve closed) ... .036 in.(0.91 mm)(5) Outside diameter of the valve seat ... 2.045 .005 in.(52.23 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm)(6) Diameter of the bore ... 2.150 in.(54.61 mm)(7) Maximum permissible depth of the bore to make the face of the valve seat smaller ... .170 in.(4.32 mm)Intake Valve (with valve seat insert)
TYPICAL ILLUSTRATION(1) Distance from the end of the valve to the valve spring washer seat ... 2.063 .015 in.(52.40 0.38 mm)(2) Depth of bore in head for valve seat insert ... .442 .002 in.(11.23 0.05 mm)(3) Diameter of valve seat insert ... 2.1500 .0005 in.(54.610 0.013 mm) Bore in head for valve seat insert ... 2.1470 .0005 in.(54.534 0.013 mm)(4) Maximum permissible width of the face of the valve seat insert ... .120 in.(3.05 mm)(5) Angle of the face of the valve seat insert ... 301/4° 1/2°(6) Distance from head of valve to cylinder head face: Maximum permissible (valve closed) ... .068 in.(1.73 mm)Minimum permissible (valve closed) ... .036 in.(0.91 mm)(7) Outside diameter of the face of the valve seat insert ... 2.045 .005 in.(52.23 0.13 mm) Maximum permissible ... 2.065 in.(52.45 mm)(8) Angle to grind face of seat insert (to get a reduction of maximum seat diameter) ... 15°