Information injection-pump assembly
BOSCH
9 400 610 326
9400610326
ZEXEL
106671-8040
1066718040
HINO
220005650A
220005650a
Rating:
Service parts 106671-8040 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1221A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106671-8040
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 610 326
9400610326
ZEXEL
106671-8040
1066718040
HINO
220005650A
220005650a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.3
3.24
3.3
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.9
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
125.5
122.5
128.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
141.2
139.2
143.2
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
10.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
149.7
146.7
152.7
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
16
13
19
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.
135
135
155
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1000--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
950
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1.5
Timer adjustment_04
Pump speed
r/min
1050
Advance angle
deg.
1.9
1.4
2.4
Timer adjustment_05
Pump speed
r/min
1150
Advance angle
deg.
4.5
4.2
4.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)RACK LIMIT
(4)Damper spring setting: DL
----------
RT=1 TH=2mm DL=6.2-0.2mm
----------
----------
RT=1 TH=2mm DL=6.2-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=25deg+-3deg
----------
----------
a=10deg+-5deg b=25deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=15deg+-5deg b=64deg+-5deg
----------
----------
a=15deg+-5deg b=64deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
Procedure
Illustration 1 g06220548
(1) TC Mark (Flywheel Housing)
(2) TC Mark (Flywheel)
Remove valve cover, and injector and rocker arm. Bring the piston of cylinder 4 to TDC.
Illustration 2 g06220554
(3) Dial Gauge
(4) Valve
(5) O-ring
Remove the #4 exhaust valve bridge arm and valve spring. Insert a small O-ring (5) so the valve does not fall into the cylinder.
Set dial gauge (3) on the tip of the valve (4).
Illustration 3 g06220569
(6) Tri - Square
(7) Flywheel Housing
(8) Flywheel
Illustration 4 g06220573
(7) Flywheel Housing
(8) Flywheel
(9) Reference Line
Turn the flywheel counterclockwise and measure the position where the tip of the valve is the highest.
Stop the flywheel at the position where the tip of the valve is the highest. Put a tri - square (6) on the flywheel housing (7) and the flywheel (8) and draw a reference line (9).Do not drop the valve (4) into the cylinder. When measuring the highest position of the tip of the valve, do not rotate the flywheel clockwise. If you go past the highest point of the valve, back up the flywheel slightly and measure the highest point of the valve. The reference line (9) indicates the TDC of the crankshaft.
Illustration 5 g06220579
Rotation Sensor Signal Interface Unit
Application: Use for reading rotation sensor signal.
(1) 9V Battery
(2) Switch
(3) 3-Terminal Regulator
(4) LED
(5) Clip (Red)
(6) Clip (Black)
(A) for Panasonic
(B) for Denso
(C) for Bosch cam angle
(D) for Bosch crank angle
((E)) Connector Side
(a) +9 V
(b) Signal
(c) GND
(d) +5 V
(e) Signal
(f) GND
Schematic to build Rotation Sensor Signal Interface.
Illustration 6 g06220581
(10) Rotation Sensor Signal Interface (Tool not available. Schematic to build tool available. Refer to Step 6.
(11) Tester
Illustration 7 g06220587
(12) Ground Terminal
(13) Output Terminal
(14) Crankshaft Position Sensor
Connect a connector of the rotation sensor signal interface unit (10) to the crankshaft position sensor (14). Connect each clip of the rotation sensor signal interface unit (10) to the same test lead color of the tester (11). Switch on the rotation sensor signal interface unit (10).
Illustration 8 g06220590
(15) Pulsar Gear
(16) 14th Tooth
(17) Missing Teeth
Turn the flywheel and make sure that the voltage of the crankshaft position sensor goes from 0→ 5 V or 5 → 0 V.
Rotate the flywheel and align the crankshaft position sensor to the part of the pulsar gear (15) that is missing teeth (17). The 14th tooth (16) from the missing teeth is standard.
Slowly turn flywheel counterclockwise and stop flywheel at the point where needle of the tester changes momentarily from 0 → 5 V, the 14th tooth.That point is where the crankshaft position sensor detects TDC.
Illustration 9 g06220608
(18) Crankshaft TDC
(19) Detection Point of Crankshaft Position Sensor TDC
Illustration 10 g06220612
(20) Interval
Set the tri - square (6) on the reference line (9) on the flywheel housing side and mark the detection point of crankshaft position sensor TDC (19) on the flywheel.
Measure the interval (20) between the crankshaft TDC (18) and the detection point of the crankshaft position sensor TDC (19).
Calculation of fuel injection timing correction 1.0 mm (0.039 in.): 0.321°.Corrected Angle = 0.321° X actual interval
Overwrite the injection timing correction value on the engine ecm registration website refer to REHS9707, "Registering Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC),
Illustration 1 g06220548
(1) TC Mark (Flywheel Housing)
(2) TC Mark (Flywheel)
Remove valve cover, and injector and rocker arm. Bring the piston of cylinder 4 to TDC.
Illustration 2 g06220554
(3) Dial Gauge
(4) Valve
(5) O-ring
Remove the #4 exhaust valve bridge arm and valve spring. Insert a small O-ring (5) so the valve does not fall into the cylinder.
Set dial gauge (3) on the tip of the valve (4).
Illustration 3 g06220569
(6) Tri - Square
(7) Flywheel Housing
(8) Flywheel
Illustration 4 g06220573
(7) Flywheel Housing
(8) Flywheel
(9) Reference Line
Turn the flywheel counterclockwise and measure the position where the tip of the valve is the highest.
Stop the flywheel at the position where the tip of the valve is the highest. Put a tri - square (6) on the flywheel housing (7) and the flywheel (8) and draw a reference line (9).Do not drop the valve (4) into the cylinder. When measuring the highest position of the tip of the valve, do not rotate the flywheel clockwise. If you go past the highest point of the valve, back up the flywheel slightly and measure the highest point of the valve. The reference line (9) indicates the TDC of the crankshaft.
Illustration 5 g06220579
Rotation Sensor Signal Interface Unit
Application: Use for reading rotation sensor signal.
(1) 9V Battery
(2) Switch
(3) 3-Terminal Regulator
(4) LED
(5) Clip (Red)
(6) Clip (Black)
(A) for Panasonic
(B) for Denso
(C) for Bosch cam angle
(D) for Bosch crank angle
((E)) Connector Side
(a) +9 V
(b) Signal
(c) GND
(d) +5 V
(e) Signal
(f) GND
Schematic to build Rotation Sensor Signal Interface.
Illustration 6 g06220581
(10) Rotation Sensor Signal Interface (Tool not available. Schematic to build tool available. Refer to Step 6.
(11) Tester
Illustration 7 g06220587
(12) Ground Terminal
(13) Output Terminal
(14) Crankshaft Position Sensor
Connect a connector of the rotation sensor signal interface unit (10) to the crankshaft position sensor (14). Connect each clip of the rotation sensor signal interface unit (10) to the same test lead color of the tester (11). Switch on the rotation sensor signal interface unit (10).
Illustration 8 g06220590
(15) Pulsar Gear
(16) 14th Tooth
(17) Missing Teeth
Turn the flywheel and make sure that the voltage of the crankshaft position sensor goes from 0→ 5 V or 5 → 0 V.
Rotate the flywheel and align the crankshaft position sensor to the part of the pulsar gear (15) that is missing teeth (17). The 14th tooth (16) from the missing teeth is standard.
Slowly turn flywheel counterclockwise and stop flywheel at the point where needle of the tester changes momentarily from 0 → 5 V, the 14th tooth.That point is where the crankshaft position sensor detects TDC.
Illustration 9 g06220608
(18) Crankshaft TDC
(19) Detection Point of Crankshaft Position Sensor TDC
Illustration 10 g06220612
(20) Interval
Set the tri - square (6) on the reference line (9) on the flywheel housing side and mark the detection point of crankshaft position sensor TDC (19) on the flywheel.
Measure the interval (20) between the crankshaft TDC (18) and the detection point of the crankshaft position sensor TDC (19).
Calculation of fuel injection timing correction 1.0 mm (0.039 in.): 0.321°.Corrected Angle = 0.321° X actual interval
Overwrite the injection timing correction value on the engine ecm registration website refer to REHS9707, "Registering Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC),