106871-8841 ZEXEL 9 400 618 307 BOSCH INJECTION-PUMP ASSEMBLY 9400618307 1068718841 220007450b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 307 9400618307

ZEXEL 106871-8841 1068718841

HINO 220007450B 220007450b

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Cross reference number

BOSCH 9 400 618 307 9400618307

ZEXEL 106871-8841 1068718841

HINO 220007450B 220007450b

Zexel num

Bosch num

Firm num

Name

106871-8841

9 400 618 307

220007450B HINO

INJECTION-PUMP ASSEMBLY
F20C * 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 134424-1020

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 4.5 4.44 4.5

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 9.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 154.4 152.4 156.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.05

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 155.5 152.5 158.5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.25

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 152.7 149.7 155.7

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 8.45

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 123.9 120.9 126.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.1 9.1 15.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_06

Adjusting point H

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 185 185 225

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 660

Advance angle deg. 0.3

Load 1/4

Timer adjustment_02

Pump speed r/min 800--

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_03

Pump speed r/min 880+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_04

Pump speed r/min 1100-50

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)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting
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SXL=9.75+-0.1mm
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Speed control lever angle

F:Full speed
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a=15.5deg+-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=44.5deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position bb (3)Use the hole above R = cc (4)Free (at delivery) (5)Set the stopper bolt (apply red paint).
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aa=11.8mm bb=2-0.5mm cc=28mm
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a=(13deg) b=46.5deg+-5deg c=29deg+-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=900r/min Ra=9.25mm
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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:

start by:a) remove cylinder headsb) remove oil pan1. Remove the carbon from the top inside surface of the cylinders with tool (A). 2. Turn the crankshaft until two pistons are at bottom center.3. Remove connecting rod caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft. 4. Push the pistons and connecting rods away from the crankshaft until the piston rings are above the cylinder block.5. Remove the two pistons (2) and the connecting rods. Keep each connecting rod cap with its respective connecting rod and piston. Put identification on each connecting rod as to its location for use at installation.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed.
6. Do Steps 2 through 5 for the remainder of the pistons.Install Pistons
Two different pistons are used in 3208 Truck Engines. One piston has a crater volume of 50.4 1.3 cm3 (3.08 .07 in.3), and the other piston has a crater volume of 58.8 1.2 cm3 (3.59 .07 in.3). Check the part number stamped on the top of the piston and refer to the parts book to be sure the correct replacement piston is used. The correct piston must be installed in the engine. If the wrong piston is installed, much damage to the engine will be the result.
1. Put clean engine oil on the piston rings, connecting rod bearings, cylinder walls and crankshaft bearing journals.2. Turn the crankshaft until the bearing journal for the pistons to be installed is at bottom center.3. Make sure the piston ring gaps are at least 120° apart on the piston. 4. Use tool (A) and install the piston in position in the same cylinder bore from which it was removed. The hole (crater) in the top of the piston must be toward (nearest) the center of the engine. For more detail about the installation of connecting rod bearings, see REMOVE AND INSTALL CONNECTING ROD BEARINGS.5. Check the bearing clearances with tool (B).6. Put 2P2506 Thread Lubricant on the threads of the bolts and contact surfaces of the nuts for the connecting rod caps.
When the connecting rod caps are installed, make sure that the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Put the cap (1) in position on the connecting rod and install the nuts. Tighten the nuts to a torque of 40 4 N m (30 3 lb.ft.). Put a mark on each nut and the end of each bolt. Tighten the nuts 60 5° more. 8. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be 0.08 to 0.84 mm (.003 to .033 in.) for new rods.9. Do Steps 1 through 8 for the remainder of the pistons.end by:a) install cylinder headsb) install oil panDisassemble Pistons
start by:a)