106871-8820 ZEXEL 9 400 618 305 BOSCH INJECTION-PUMP ASSEMBLY 9400618305 1068718820 220801540a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 305 9400618305

ZEXEL 106871-8820 1068718820

HINO 220801540A 220801540a

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Buy INJECTION-PUMP ASSEMBLY 106871-8820 zexel genuine, new aftermarket engine parts with delivery

Service parts 106871-8820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5302

3. GOVERNOR 105489-3010

4. SUPPLY PUMP

105237-1341

5. AUTOM. ADVANCE MECHANIS 105636-0570

6. COUPLING PLATE 105662-0500

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5100

11. Nozzle and Holder 23600-1530

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-5400

14. NOZZLE

105015-4700

15. NOZZLE SET

Include in #1:

106871-8820 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 305 9400618305

ZEXEL 106871-8820 1068718820

HINO 220801540A 220801540a

Zexel num

Bosch num

Firm num

Name

106871-8820

9 400 618 305

220801540A HINO

INJECTION-PUMP ASSEMBLY
EF750 * K 14CD INJECTION PUMP ASSY PE8P PE

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 4.4 4.34 4.4

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 9.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 120 117 123

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 121.8 119.8 123.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 145 142 148

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 5.4

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.5 8.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 160

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_06

Adjusting point H

Rack position 7.6+-0.5

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 126 121 131

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Timer adjustment

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3.5 3.2 3.8

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 (N = N1) (3)Damper spring setting
----------
SXL=10.4+0.2mm N1=350r/min
----------

Speed control lever angle

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

----------
a=21.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=50mm
----------
a=39deg+-3deg b=39deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)After assembling lever on end of solenoid (2)Use the hole at R = aa
----------
aa=30mm
----------
a=39deg+-5deg b=40deg+-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:

start by:a) remove exhaust manifoldb) remove air inlet manifoldc) remove valve coversd) remove fuel injection linese) remove fuel injection nozzles1. Remove the coolant from the cooling system. 2. Remove clamp (2) from water sleeves (1) in each cylinder head. Push the water sleeves into the timing gear cover with tool (A) and a screwdriver. 3. Remove bolt (3) from the bracket on the dipstick tube. 4. Remove bolts (4) and stud (5) from the heads.
Make sure the fuel injection nozzles are removed before the cylinder heads are removed. The fuel injection nozzles go through the cylinder heads and the nozzle tips can be broken off if the nozzles are not removed from the heads.
5. Install tooling (B) and fasten a hoist. Remove bolts (7), cylinder head (6) and the gasket. The weight of the cylinder head is 54 kg (120 lb.).Install Cylinder Heads
1. Clean the contact surfaces of the cylinder head and cylinder block. Make sure the surfaces are clean and dry. Install a new cylinder head gasket. Clean the bore in the cylinder head for the water sleeves. Put oil on the seals on the water sleeves.2. Install tooling (B) in the cylinder head. Fasten a hoist and put the cylinder head in position on the cylinder block.3. Put 6V4876 Molykote Lubricant on the bolt threads and install the bolts that hold the cylinder head in their correct location. Tighten the bolts in the cylinder head according to the HEAD BOLT TORQUE CHART.
The higher cylinder head bolt torque may be used on earlier engines ONLY if the bolts are replaced with the later higher strength bolts (seven dash marks on the bolt head). If the earlier bolts are tightened to the later torque specification, they may yield (stretch) and lose their clamping force.
4. Install water sleeve into cylinder head with tool (A). Install the clamp on the water sleeves.5. Fill the cooling system with coolant to the correct level. end by:a) install fuel injection nozzlesb) install rocker shafts and push rodsc) install valve coversd) install air inlet manifolde) install exhaust manifold
Illustration 1. Bolt head identification.Disassemble Cylinder Heads
start by: a) remove cylinder heads1. Fasten a hoist and put the cylinder head in position on tool (A). Use adapter plates (1) from tooling (A) to hold the head in place. 2. Put the valve springs under compression with tool (C). 3. Remove the locks from the valves. Earlier engines have an inner valve spring. Later engines have only one valve spring and a spacer instead of inner spring.4. Remove tool (C), retainer, spring, washer and valve from the cylinder head. Put identification on the valve as to its location in the cylinder head. 5. Check the valve spring force with tool (B). For the correct spring force, see the subject VALVES in SPECIFICATIONS.6. Do Steps 2 through 5 for the remainder of the valves.7. Remove the valve seat inserts with tooling (D). The valve guides are part of the cylinder head. Measure the bore in each valve guide 19.0