Information injection-pump assembly
BOSCH
9 400 619 865
9400619865
ZEXEL
106672-3702
1066723702
HINO
220204572A
220204572a
Rating:
Service parts 106672-3702 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
106672-3702
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 865
9400619865
ZEXEL
106672-3702
1066723702
HINO
220204572A
220204572a
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
134424-1420
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
4.5
4.4
4.5
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
132.5
130.5
134.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
24
24
Boost pressure
mmHg
180
180
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11
8
14
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
R1-0.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
117.5
111.5
123.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
134
129
139
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
R1-0.7
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(10.2)
Boost pressure
kPa
10.7
10.7
10.7
Boost pressure
mmHg
80
80
80
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)Main spring setting
(6)Set idle sub-spring
----------
K=8 BCL=0.7+-0.1mm
----------
----------
K=8 BCL=0.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=1deg+-5deg b=18deg+-5deg
----------
----------
a=1deg+-5deg b=18deg+-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=25deg+-5deg b=70deg+-5deg
----------
aa=0r/min bb=1-0.5mm
----------
a=25deg+-5deg b=70deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Disassembly and Reassembly of General Parts
Oil seals
When installing oil seals, observe the following.Installation of Oil Seals to Housings
(a) Check the seal lip for scratches and damage, and be sure to position the lip correctly.(b) Apply a small amount of grease to the periphery (housing contact surface) of the oil seal before installation.(c) Use an oil seal driver that guides the seal lip and presses the seal periphery, as shown in the diagram on the right. Striking the oil seal directly with a hammer causes seal damage and results in oil leaks.
Oil seal driverInstallation of Oil Seals to Shafts
(a) Apply grease to the oil seal lip.(b) Use an oil seal guide similar to the one shown in the diagram when installing an oil seal over the stepped portion, splines, threads or key grooves.
Oil seal guideO-rings
Use an O-ring guide similar to the one shown in the diagram when installing an O-ring over the stepped portion, splines, threads or key grooves. Be sure to apply a small amount of grease to the O-ring before installation.
O-ring guideBearings
Bearing Driver(1) When installing a bearing, be sure to push the inner or outer race that fits into the installation position. (When the inner race fits into the installation position, push the inner race into position. When the outer race fits into the installation position, push the outer race into position.) Be sure to use a bearing driver similar to the one shown in the diagram.(2) Use of a press minimizes the impact on the bearing and ensures proper installation.
Using press for bearing installationLock Plates
Be sure to bend lock plates. The diagram on the right shows the methods of bending representative lock plates.
Bending lock plateSplit Pins and Spring Pins
Generally, new split pins should be installed whenever split pins are removed. Be sure to bend split pins. Be sure to check spring pins for secure installation.Engine Inspection Record Sheet
1. Measurement of Cylinder Bore Diameter2. Measurement of Clearance between Valve Stem and Valve Guide, and Valve Stem Diameter3. Measurement of Valve Sinkage, Seat Width and Valve Margin4. Measurement of Distortion of Cylinder Head Bottom Surfaces5. Measurement of Oil Clearance of Connecting Rod Bearing6. Measurement of Rocker Arm Inside Diameter and Shaft Diameter7. Measurement of Piston Pin Bore Diameter and Piston Pin Diameter8. Measurement of Valve Clearance9. Measurement of Injection Pressure of Fuel Injection Nozzle10. Measurement of Clearance between Camshaft Journal Bore Diameter and Camshaft Bushing11. Measurement of Crankshaft End PlayEngine Inspection Record Sheet No. 1 Engine Inspection Record Sheet No. 2 Engine Inspection Record Sheet No. 3 Engine Inspection Record Sheet No. 4 Engine Inspection Record Sheet No. 5 Engine Inspection Record Sheet No. 6 Engine Inspection Record Sheet No. 7 Engine Inspection Record Sheet No. 8 Engine Inspection Record Sheet No. 9 Engine Inspection Record Sheet No. 10 Engine Inspection Record Sheet No. 11
Oil seals
When installing oil seals, observe the following.Installation of Oil Seals to Housings
(a) Check the seal lip for scratches and damage, and be sure to position the lip correctly.(b) Apply a small amount of grease to the periphery (housing contact surface) of the oil seal before installation.(c) Use an oil seal driver that guides the seal lip and presses the seal periphery, as shown in the diagram on the right. Striking the oil seal directly with a hammer causes seal damage and results in oil leaks.
Oil seal driverInstallation of Oil Seals to Shafts
(a) Apply grease to the oil seal lip.(b) Use an oil seal guide similar to the one shown in the diagram when installing an oil seal over the stepped portion, splines, threads or key grooves.
Oil seal guideO-rings
Use an O-ring guide similar to the one shown in the diagram when installing an O-ring over the stepped portion, splines, threads or key grooves. Be sure to apply a small amount of grease to the O-ring before installation.
O-ring guideBearings
Bearing Driver(1) When installing a bearing, be sure to push the inner or outer race that fits into the installation position. (When the inner race fits into the installation position, push the inner race into position. When the outer race fits into the installation position, push the outer race into position.) Be sure to use a bearing driver similar to the one shown in the diagram.(2) Use of a press minimizes the impact on the bearing and ensures proper installation.
Using press for bearing installationLock Plates
Be sure to bend lock plates. The diagram on the right shows the methods of bending representative lock plates.
Bending lock plateSplit Pins and Spring Pins
Generally, new split pins should be installed whenever split pins are removed. Be sure to bend split pins. Be sure to check spring pins for secure installation.Engine Inspection Record Sheet
1. Measurement of Cylinder Bore Diameter2. Measurement of Clearance between Valve Stem and Valve Guide, and Valve Stem Diameter3. Measurement of Valve Sinkage, Seat Width and Valve Margin4. Measurement of Distortion of Cylinder Head Bottom Surfaces5. Measurement of Oil Clearance of Connecting Rod Bearing6. Measurement of Rocker Arm Inside Diameter and Shaft Diameter7. Measurement of Piston Pin Bore Diameter and Piston Pin Diameter8. Measurement of Valve Clearance9. Measurement of Injection Pressure of Fuel Injection Nozzle10. Measurement of Clearance between Camshaft Journal Bore Diameter and Camshaft Bushing11. Measurement of Crankshaft End PlayEngine Inspection Record Sheet No. 1 Engine Inspection Record Sheet No. 2 Engine Inspection Record Sheet No. 3 Engine Inspection Record Sheet No. 4 Engine Inspection Record Sheet No. 5 Engine Inspection Record Sheet No. 6 Engine Inspection Record Sheet No. 7 Engine Inspection Record Sheet No. 8 Engine Inspection Record Sheet No. 9 Engine Inspection Record Sheet No. 10 Engine Inspection Record Sheet No. 11