106871-8911 ZEXEL 9 400 618 309 BOSCH INJECTION-PUMP ASSEMBLY 9400618309 1068718911 220007540b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 309 9400618309

ZEXEL 106871-8911 1068718911

HINO 220007540B 220007540b

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Service parts 106871-8911 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7910

3. GOVERNOR 105489-3140

4. SUPPLY PUMP 105237-4050

5. AUTOM. ADVANCE MECHANIS 105683-0010

6. COUPLING PLATE 105664-0461

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7183

11. Nozzle and Holder 236002252A

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/24.5(250)

13. NOZZLE-HOLDER 105030-3482

14. NOZZLE

105015-8710

15. NOZZLE SET

Include in #1:

106871-8911 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 309 9400618309

ZEXEL 106871-8911 1068718911

HINO 220007540B 220007540b

Zexel num

Bosch num

Firm num

Name

106871-8911

9 400 618 309

220007540B 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 D

Rack position 9.25+-0. 5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 143.5 139.5 147.5

Fixing the lever *

Injection quantity adjustment_05

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_06

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_07

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 -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min 800--

Advance angle deg. 1 0.7 1.3

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.7 1.3

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100-50

Advance angle deg. 4.75 4.45 5.05

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 (4)When air cylinder is operating.
----------
SXL=9.75+-0.1mm
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Speed control lever angle

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

----------
a=15.5deg+-5deg

0000000901

F:Full load I:Idle (1)Set point I (at air cylinder operation) (2)Use the hole at R = aa (3)Stopper bolt setting
----------
aa=39mm
----------
a=39deg+-5deg b=44.5deg+-3deg c=(14.5deg)

Stop lever angle

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

----------
a=15deg+-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)
----------
N1=900r/min Ra=9.25mm
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0000001601 LEVER

1. Air cylinder adjustment (1)With the load lever in the idle position, temporarily set the distance between the load lever A and the air cylinder D at approximately L. (2)Set N1 and apply P1 to the air cylinder D. (3)Adjust set bolt (D) to obtain R1 at the same speed. (4)Lock using nut C. (5)Apply positive pressure several times. (6)Confirm that the load lever A returns to the idling position N2 at pressure P2. (7)Also at P1 confirm R1 (N1).
----------
L=(5)mm R1=3.8mm N1=400r/min N2=(225)r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------

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) Maximum permissible temperature of the gear for installation on the camshaft (do not use a torch) ... 315°C (600°F)(2) Tight fit between the gear and camshaft ... 0.037 to 0.123 mm (.0015 to .0048 in)(3) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 0.013 mm (2.7500 .0005 in) Bore in front bearing for the camshaft (after assembly) ... 69.969 0.048 mm (2.7547 .0019 in)Bore in the other six bearings for the camshaft (after assembly) ... 69.982 0.061 mm (2.7552 .0024 in)(4) Thickness of thrust plate (new) ... 4.65 0.03 mm (.183 .001 in) End play of the camshaft ... 0.10 to 0.26 mm (.004 to .010 in) (5) Height of camshaft lobes.To find lobe height, use the procedure that follows:A. Measure camshaft lobe height (5).B. Measure base circle (7).C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).D. Specified camshaft lobe lift (6) is:4W2430 Camshaft Assembly
a. Exhaust lobe ... 10.211 mm (.4020 in)b. Intake lobe ... 10.211 mm (.4020 in)7W3797 Camshaft Assembly
a. Exhaust lobe ... 10.210 mm (.4020 in)b. Intake lobe ... 10.212 mm (.4021 in)Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is 0.13 mm (.005 in).Intake Valve Timing
1. Check the No. 1 intake valve clearance with the engine stopped. The valve clearance must be 0.30 to 0.46 mm (.012 to .018 in). If the valve clearance is not in this range, adjust the clearance to 0.38 mm (.015 in).2. Mark Top Center Position of the crankshaft on the vibration damper or pulley.3. Use a dial indicator to measure the intake valve movement.4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the intake valve is 1.91 mm (.075 in) off its seat in the opening sequence.At this point the crankshaft Top Center Position Mark must be in position as follows: Engines with the 4W2430 Camshaft Assembly ... 7 2° After Top CenterEngines with the 7W3797 Camshaft Assembly ... 1 2° After Top CenterChecking Valve-Camshaft Timing (field procedure)
The following factory procedure as described in the December 11, 1989 Service Magazine article will simplify in the field checking of the camshaft timing procedures.1. Set the No. 3 intake bridge adjustment.2. Set the No. 3 intake valve clearance.3. Install the bolt in the flywheel with No. 1 piston at top center.4. Install the dial indicator (magnetic base) to No. 3 intake bridge.5. Remove the bolt from the flywheel.6. Set the gauge at zero and rotate the engine in the normal direction of operation (counterclockwise as seen from the flywheel end) until dial travel stops.The following chart indicates the correct setting.