Information injection-pump assembly
BOSCH
9 400 610 892
9400610892
ZEXEL
106671-8771
1066718771
Rating:
Service parts 106671-8771 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1970B
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106671-8771
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 610 892
9400610892
ZEXEL
106671-8771
1066718771
Zexel num
Bosch num
Firm num
Name
9 400 610 892
S220204561A HINO
INJECTION-PUMP ASSEMBLY
A * K 14CA PE6P,6PD PE
A * K 14CA PE6P,6PD PE
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
3.9
3.84
3.9
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
10.3
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
196
193
199
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
58.7
58.7
Boost pressure
mmHg
440
440
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.6+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
10.5
7.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
170
170
180
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-2
Boost pressure
kPa
14.7
12
17.4
Boost pressure
mmHg
110
90
130
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(10.3)
Boost pressure
kPa
46.7
41.4
52
Boost pressure
mmHg
350
310
390
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
3.5
3.2
3.8
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=13 BCL=2+-0.1mm
----------
----------
K=13 BCL=2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-5deg b=21deg+-5deg
----------
----------
a=7deg+-5deg b=21deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=10deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=10deg+-5deg b=70deg+-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=1025r/min Ra=10.3mm
----------
----------
N1=1025r/min Ra=10.3mm
----------
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:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
The diesel exhaust fluid (DEF) quality sensors are susceptible to seeing the following fault codes.
Table 1
J1939 CDL Code Description
3516-2 3100-2 Aftertreatment #1 DEF Concentration: Erratic, Intermittent or Incorrect
3516-12 3100-12 Aftertreatment #1 DEF Concentration: Failure
3516-16 E1365 High Aftertreatment #1 DEF Concentration
3516-18 E1364 Low Aftertreatment #1 DEF Concentration Solution
The latest software available in SIS has improvements in it related to the DEF quality sensor and these fault codes.
Ensure that the latest engine and aftertreatment software is installed prior to any hardware replacements.
Ensure that the latest DCU software is installed ( 539-3577 Engine Software (24V DCU) or 539-3576 Engine Software (12V DCU)).
In addition to the troubleshooting for these fault codes in SIS web, ensure that DEF quality is checked with both a refractometer and the 466-8796 Test Strips as outlined in Diesel Exhaust Fluid Quality - Test procedure in SIS.
Keep the DEF tank full when machine/engine will not be operated for an extended period of time to help reduce manifold exposure to ammonia gases in the DEF tank.Have seen cases of contamination where the test strips will not detect it if contamination is not hydrocarbon-based. In these instances, the DEF will appear to be cloudy when doing a visual comparison to a good, clean DEF sample.While working through issues related to these particular fault codes, email Blunier_Derek_W to provide troubleshooting information and documentation as to what was found.Information to Provide
PSRPT with histograms
Application History File
All troubleshooting resultsIf the DEF manifold does get replaced, provide the following:
Dealer code
Workorder number
Serial number
Hours at repair
DEF sample collected from top level of tank to be returned along with the DEF manifoldA Send It Back (SIB) will be created to get the DEF manifold returned.Downloading an Application History File
Illustration 1 g06233931
Click the appropriate ECM.
Click "Information".
Click "Warranty Report".
Illustration 2 g06233935
Click "ECM Information".
Click the "Yes" button.
Illustration 3 g06233938
Click "Additional Service".
Click the "Save" button.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
The diesel exhaust fluid (DEF) quality sensors are susceptible to seeing the following fault codes.
Table 1
J1939 CDL Code Description
3516-2 3100-2 Aftertreatment #1 DEF Concentration: Erratic, Intermittent or Incorrect
3516-12 3100-12 Aftertreatment #1 DEF Concentration: Failure
3516-16 E1365 High Aftertreatment #1 DEF Concentration
3516-18 E1364 Low Aftertreatment #1 DEF Concentration Solution
The latest software available in SIS has improvements in it related to the DEF quality sensor and these fault codes.
Ensure that the latest engine and aftertreatment software is installed prior to any hardware replacements.
Ensure that the latest DCU software is installed ( 539-3577 Engine Software (24V DCU) or 539-3576 Engine Software (12V DCU)).
In addition to the troubleshooting for these fault codes in SIS web, ensure that DEF quality is checked with both a refractometer and the 466-8796 Test Strips as outlined in Diesel Exhaust Fluid Quality - Test procedure in SIS.
Keep the DEF tank full when machine/engine will not be operated for an extended period of time to help reduce manifold exposure to ammonia gases in the DEF tank.Have seen cases of contamination where the test strips will not detect it if contamination is not hydrocarbon-based. In these instances, the DEF will appear to be cloudy when doing a visual comparison to a good, clean DEF sample.While working through issues related to these particular fault codes, email Blunier_Derek_W to provide troubleshooting information and documentation as to what was found.Information to Provide
PSRPT with histograms
Application History File
All troubleshooting resultsIf the DEF manifold does get replaced, provide the following:
Dealer code
Workorder number
Serial number
Hours at repair
DEF sample collected from top level of tank to be returned along with the DEF manifoldA Send It Back (SIB) will be created to get the DEF manifold returned.Downloading an Application History File
Illustration 1 g06233931
Click the appropriate ECM.
Click "Information".
Click "Warranty Report".
Illustration 2 g06233935
Click "ECM Information".
Click the "Yes" button.
Illustration 3 g06233938
Click "Additional Service".
Click the "Save" button.