Information injection-pump assembly
BOSCH
9 400 618 285
9400618285
ZEXEL
106871-8602
1068718602
HINO
220006971A
220006971a
Rating:
Service parts 106871-8602 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2240B
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
106871-8602
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 285
9400618285
ZEXEL
106871-8602
1068718602
HINO
220006971A
220006971a
Zexel num
Bosch num
Firm num
Name
106871-8602
9 400 618 285
220006971A HINO
INJECTION-PUMP ASSEMBLY
F17E K
F17E K
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
134424-0820
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4.8
4.74
4.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
136
132.5
139.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
9.7
6.7
12.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
136
134
138
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
135.5
129.5
141.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
138
132
144
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.2
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
137.5
131.5
143.5
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
150
145
155
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
710--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
660
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
800
Advance angle
deg.
0.7
0.4
1
Load
4/4
Timer adjustment_04
Pump speed
r/min
880
Advance angle
deg.
0.7
0.4
1
Load
3/4
Timer adjustment_05
Pump speed
r/min
1100
Advance angle
deg.
5.25
4.95
5.55
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=G17
----------
----------
T1=G17
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=35deg+-5deg b=(44deg)+-3deg
----------
aa=41mm
----------
a=35deg+-5deg b=(44deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=45mm
----------
a=(40deg)+-5deg b=8deg+-5deg
----------
aa=45mm
----------
a=(40deg)+-5deg b=8deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
Adjustment of the rack sensor (-2320)
1. Rack limit adjustment
(1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position.
(2)Install the rod (e) to the block (c).
(3)At the rack limit, set the distance between the pump end face and the rod (E) to L1.
2. Rack sensor
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at N1.
(3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V).
(5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=900r/min Ra=R1(12.1)+0.2mm
----------
----------
L=43+-0.1mm N1=900r/min Ra=R1(12.1)+0.2mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
Illustration 8 g01455580
(6) 294-3395 Exhaust Support Assembly
Make four mounting holes for 294-3395 Exhaust Support Assembly (6) in the location (designated with a circle) which is shown in Illustration 8.
Illustration 9 g01456256
(17) 8T-4223 Hard Washers (18) 8T-4244 Nuts (19) 8T-4648 Bolt (20) 8T-4956 Bolt (21) 8T-6868 Bolts
Install exhaust support assembly (6) by using two 8T-6868 Bolts (21), one 8T-4648 Bolt (19), one 8T-4956 Bolt (20), four 8T-4223 Hard Washers (17), and four 8T-4244 Nuts (18). Refer to Illustration 9.
Illustration 10 g01456263
(9) 295-3044 Exhaust Support Groups (Lower half)
Remove the upper clamp from each 295-3044 Exhaust Support Group (9) by removing the two bolts and two hard washers. Keep the four bolts, the four hard washers, and the two upper clamps together. These parts will be reinstalled in Step 15.
Use four 8T-4956 Bolts (20) and four 8T-4223 Hard Washers (17) to install both 295-3044 Exhaust Support Groups (9) to exhaust support assembly (6). Refer to Illustration 10.
Illustration 11 g01456281
(5) 294-3065 Diesel Particulate Filter Group
To facilitate handling, remove the filter units from 294-3065 Diesel Particulate Filter Group (5) by removing the two clamps (including gaskets) closest to the rectangular intake manifold. Place the filter units, clamps, and gaskets aside.Note: Handle the removed filter units with extra care, as the internal structure is subject to damage due to impact, dropping, etc. Do not allow the inside of the filter units to get wet.
Install 294-3065 Diesel Particulate Filter Group (5) by aligning the mounting holes in the intake manifold with the mounting holes in the welded exhaust support assembly (7). Secure the intake manifold to the exhaust support assembly by using two 8T-4956 Bolts (20), two 8T-4223 Hard Washers (17), and two 8T-4244 Nuts (18). Refer to Illustration 11.
Reattach the lower filter unit to the intake manifold by reinstalling the clamp and the gasket that was removed in Step 12. Repeat for the upper filter unit.
Illustration 12 g01456285
Align the mounting holes in the upper half of 295-3044 Exhaust Support Group (9) with the mounting holes in the lower half of the exhaust support group (9). Reinstall the two bolts (9a) and the two hard washers (9b). Repeat for the other exhaust support group (9). Refer to Illustration 12.
Connect the straight end of exhaust tube assembly (8) to the manifold inlet pipe of the Diesel Particulate Filter Group. Use one 190-5341 Clamp (3)
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Hino
106871-8602
9 400 618 285
220006971A
INJECTION-PUMP ASSEMBLY
F17E
F17E