Information injection-pump assembly
BOSCH
9 400 618 292
9400618292
ZEXEL
106871-8681
1068718681
HINO
220007370B
220007370b

Rating:
Service parts 106871-8681 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236002252A
12.
Open Pre:MPa(Kqf/cm2)
15.7(160)/24.5(250)
15.
NOZZLE SET
Include in #1:
106871-8681
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 292
9400618292
ZEXEL
106871-8681
1068718681
HINO
220007370B
220007370b
Zexel num
Bosch num
Firm num
Name
106871-8681
9 400 618 292
220007370B HINO
INJECTION-PUMP ASSEMBLY
F20C K
F20C 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
134424-1020
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
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
4.5
4.44
4.5
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
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
After startup boost setting
Timer adjustment
Pump speed
r/min
660
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_02
Pump speed
r/min
800--
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_03
Pump speed
r/min
880+50
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_04
Pump speed
r/min
1100-50
Advance angle
deg.
4.75
4.45
5.05
Load
4/4
Remarks
Finish
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
----------
SXL=9.75+-0.1mm
----------
----------
SXL=9.75+-0.1mm
----------
Speed control lever angle

F:Full speed
----------
----------
a=15.5deg+-5deg
----------
----------
a=15.5deg+-5deg
0000000901

F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=65mm
----------
a=10deg+-5deg b=44.5deg+-3deg
----------
aa=65mm
----------
a=10deg+-5deg b=44.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=15deg+-5deg b=64deg+-5deg
----------
----------
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
----------
----------
N1=900r/min Ra=9.25mm
----------
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:
2. Put transmission in direct gear and the differential in the highest speed ratio. Operate vehicle at maximum engine speed and increase chassis dynamometer load until a speed of 50 rpm less than rated speed is reached (continuity light should be on). Maintain this speed for one minute and record the engine speed and wheel horsepower. If horsepower is low and poor maintenance is suspected, remove air cleaner and check horsepower again to see if a plugged air cleaner could be the problem.3a. If the wheel horsepower is correct, find the set point (balance point) of the engine (speed at which the load stop pin just touches the torque spring or stop bar). At this point the continuity light should flicker (go off and on dimly).If the set point (balance point) is correct, then the low power complaint cannot be validated. No further test or repairs are necessary.If the set point (balance point) is low, see Procedure No. 4.3b. If the wheel horsepower is below the correct value, find the set point (balance point) of the engine (speed at which the load stop pin just touches the torque spring or stop bar). At this point the continuity light should flicker (go off and on dimly).If the set point (balance point) is correct, see Procedure No. 5.If the set point (balance point) is low, see Procedure No. 4.4. If the set point (balance point) is low, the high idle will have to be increased to raise the set point (balance point) to the correct rpm (the point at which the continuity light just comes on). If the set point (balance point) is still low and high idle has been adjusted to maximum, disengage clutch while maximum throttle position is maintained. Now observe high idle rpm and, if lower than previously adjusted, check frame-to-engine-mount. A damaged or loose engine mount may put the linkage in a bind and prevent maximum governor position at load conditions.5. If the set point (balance point) was correct and the wheel horsepower was low, install the 1U5470 Engine Pressure Group and do the wheel horsepower test again as shown in Procedure No 2.At full load rpm, measure the boost and the fuel pressure. See Fuel Setting and Related Information Fiche to find the correct boost pressure for a particular engine (since the engine is in vehicle, be sure to make reference to the General Notes in the Fuel Setting and Related Information Fiche to determine the correct boost pressure with air cleaner and muffler installed). If boost is low, check connections ahead of turbine side of turbocharger for exhaust leaks and connections after compressor side of turbocharger for inlet air leaks.6. Check the air inlet restriction and exhaust back pressure.Air flow through the air cleaner and piping must not have a vacuum restriction (negative pressure difference between atmospheric air and air that has gone through air cleaner) of more than 635 mm (25 in) of water. Back pressure from the exhaust (pressure difference measurement between
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Hino
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106871-8681
9 400 618 292
220007370B
INJECTION-PUMP ASSEMBLY
F20C
F20C