106871-8810 ZEXEL 9 400 618 304 BOSCH INJECTION-PUMP ASSEMBLY 9400618304 1068718810 220007360a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 304 9400618304

ZEXEL 106871-8810 1068718810

HINO 220007360A 220007360a

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Cross reference number

BOSCH 9 400 618 304 9400618304

ZEXEL 106871-8810 1068718810

HINO 220007360A 220007360a

Zexel num

Bosch num

Firm num

Name

106871-8810
106871-8850

9 400 618 304

220007360A 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 A

Rack position 9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 139 137 141

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 140 137 143

Fixing the lever *

Injection quantity adjustment_03

Adjusting point F

Rack position 3.9+-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 *

Injection quantity adjustment_04

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140

Fixing the lever *

Remarks
After startup boost setting

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Supplied with torque spring not set. (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting (7)Set idle at point K (N = N2, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N3).
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RT=0.8 TH=2.9mm SXL=10+-0.1mm N1=300r/min N2=325r/min R2=3.9mm N3=1100r/min Q1=2mm3/st
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Speed control lever angle

F:Full speed
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a=(16deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=65mm
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a=10deg+-5deg b=44deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=10deg+-5deg b=64deg+-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=1100r/min Ra=9.2mm
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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)-
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a=(80deg)

Information:

1. Remove carbon seal dam (2) with pliers. Remove compression seal (1). 2. Install a new compression seal on the nozzle. Install a new carbon seal dam with tool (B).3. Make sure the bore in the cylinder head and the fuel inlet fittings are clean.4. Install new O-ring seals on adapter (3) and fuel injection nozzle (4).5. Install the fuel injection nozzle in the head. Turn and push the nozzle into its correct position. Never put lubricant on the nozzle or bore in the cylinder head. 6. Install the adapter in the head. Connect the nozzle and fuel injection line to the adapter. Tighten the nuts to a torque of 40 7 N m (30 5 lb.ft.).7. Install the spacer and clamp (5) that hold the nozzle to the cylinder head. end by:a) install rocker shaftsDisassemble Fuel Injection Nozzles (9N3979 & 1W5829)
start by:a) remove fuel injection nozzles Do not disassemble any nozzle until test has shown it is needed. Check each nozzle with tool (A) for leakage, the pressure, at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do not clean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that cannot be corrected with an adjustment or cleaning and can cause engine damage. See TESTING 9N3979 & 1W5829 FUEL INJECTION NOZZLES in TESTING AND ADJUSTING.
Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled.
1. Remove cap (1) from the fuel injection nozzle.2. Put the nozzle in tool (B). Put tool (B) and the nozzle in a vise. Do not put any part of a nozzle directly in a vise. Loosen locknut (2) while the lift adjustment screw is held. Turn the lift adjustment screw (3) counterclockwise one turn. Hold the lift adjustment screw (3) with a 5/64" hex wrench and remove the locknut (2).
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned.
3. Loosen the locknut (4) that holds the pressure adjustment screw. Use tool (D) to hold the pressure adjustment screw. 4. While the nozzle is held in one hand, tilt the nozzle and remove the pressure adjusting screw and locknut, spring, seat and valve. 5. If the valve does not slide out of the nozzle, install tool (C) and remove valve as follows: a) Push valve into nozzle with tool (C) until valve is against bottom of nozzle.b) Push down on body of tool (C) to engage collet on valve with tool (C). c) Turn nut counterclockwise and remove valve from the nozzle body. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must