Information injection-pump assembly
BOSCH
9 400 619 698
9400619698
ZEXEL
107691-3121
1076913121
HINO
220009481A
220009481a
Rating:
Service parts 107691-3121 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
23600-2970A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-3121
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 698
9400619698
ZEXEL
107691-3121
1076913121
HINO
220009481A
220009481a
Zexel num
Bosch num
Firm num
Name
9 400 619 698
220009481A HINO
INJECTION-PUMP ASSEMBLY
J08C-TE * K 14CG TICS MD-TI6 TICS
J08C-TE * K 14CG TICS MD-TI6 TICS
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0920
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
01
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
16
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
5.1
5.07
5.13
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
12.8
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
135
132
138
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
6.1+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
PS407910-303*
V
V1+0.05+
-0.01
PS407910-303*
mm
5+-0.03
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.8)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
135
133
137
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+2.85
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
149.5
143.5
155.5
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Boost compensator adjustment
Pump speed
r/min
350
350
350
Rack position
R2-2.15
Boost pressure
kPa
26.7
25.4
28
Boost pressure
mmHg
200
190
210
Boost compensator adjustment_02
Pump speed
r/min
350
350
350
Rack position
R2[R1-2]
Boost pressure
kPa
48
48
48
Boost pressure
mmHg
360
360
360
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1120
Advance angle
deg.
0
-0.3
0
Timer adjustment_03
Pump speed
r/min
1250-50
Advance angle
deg.
-1.5
-1.8
-1.2
Remarks
Finish
Finish
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=AE20 BCL=2.15+-0.1mm
----------
----------
T1=AE20 BCL=2.15+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=50mm
----------
a=8deg+-5deg b=40deg+-3deg
----------
aa=50mm
----------
a=8deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the lever in the normal position (fully loosen the stopper screw). Tighten the stopper screw so that the speed lever contacts the stop lever.
(2)Pump speed aa, rack position bb
(3)Use the hole above R = cc
----------
aa=0r/min bb=1.5+-0.1mm cc=40mm
----------
a=15deg+-5deg b=35deg+-5deg
----------
aa=0r/min bb=1.5+-0.1mm cc=40mm
----------
a=15deg+-5deg b=35deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=5.1+-0.03mm
----------
a=(80deg)
----------
aa=5.1+-0.03mm
----------
a=(80deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 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=1250r/min Ra=R1(12.8)+2.85mm
----------
----------
N1=1250r/min Ra=R1(12.8)+2.85mm
----------
Information:
start by:a) separation of governor from fuel injection pump housing 1. Remove the ring (3) and pin (1) that hold seat (2). 2. Remove seat (2), bolt (4), washers (6) and spring (5).3. Remove the sleeve and bearing assembly from the cylinder and weight assemblies. 4. Remove ring (7) from sleeve (8).5. Remove bearing (9) and washers (10) from sleeve (8). 6. Remove valve (12) from piston (11). 7. Remove ring (15) that holds the weight assembly to cylinder (16).8. Remove weight assembly (13) from the cylinder.9. Remove piston (11) and sleeve (14) from the cylinder. Remove the O-ring seal from sleeve (14). 10. Remove speed limiter plug (20), spring and plunger from the governor housing (19).11. Remove torque spring assembly (17). 12. Remove bolt (21) and lock that hold lever (22) to shaft (18).13. Remove lever (22) and shaft from the housing.14. Remove the seal from housing (19).15. Remove the bearings and plug from the housing with tooling (A). 16. Remove two bolts (23), lock, lever arm (26) and shaft (25) from idle screw housing (24).17. Remove the two seals, bearings and plug from housing (24) with tooling (A).Assemble Governor
1. Use tooling (A) to install inner seal (3) in idle screw housing (2). Install seal (3) so the lip of the seal is toward bearing (4). Put clean engine oil on the lips of the seals.2. Use tooling (A) to install bearing (1) and the outer seal. Install the outer seal with the lip of the seal toward the outside. Install bearing (4). 3. Install bearing (6) in governor housing (8) to dimension (Y) or .897 .010 in. (22.97 0.25 mm) with tooling (A). Install bearing (5) in the governor housing to dimension (X) or 2.385 .005 in. (60.58 0.13 mm) from bearing (6). Install plug (7) in the governor housing. 4. Use tooling (A) to install the seal in governor housing (8). Install the seal with the lip of the seal toward the inside.5. Install torque spring assembly (9) on the governor housing. Install the lock and bolts that hold it. See RACK SETTING INFORMATION for the correct adjustment of the torque spring assembly. 6. Put lever assembly (11) in position in the governor housing. Install shaft (10) in the housing through the lever. Install the lock and bolt that hold the lever to the shaft. 7. Install speed limiter plunger (14), spring (13) and plug (12) in the governor housing. 8. Install O-ring seal (17) on sleeve (18).9. Install piston (16) and the sleeve in cylinder (15). 10. Put weight assembly (19) on cylinder (15). Install the ring that holds the weight assembly on the cylinder. 11. Install valve (21) in piston (16).12. Install bearing and washers (22) on sleeve (20). Install the ring that holds the washers and bearing on the sleeve.13. Install the sleeve assembly on valve (21). 14. Install bolt (23) in seat (24). Install the washers and spring in the seat.15. Put the seat in position on
1. Use tooling (A) to install inner seal (3) in idle screw housing (2). Install seal (3) so the lip of the seal is toward bearing (4). Put clean engine oil on the lips of the seals.2. Use tooling (A) to install bearing (1) and the outer seal. Install the outer seal with the lip of the seal toward the outside. Install bearing (4). 3. Install bearing (6) in governor housing (8) to dimension (Y) or .897 .010 in. (22.97 0.25 mm) with tooling (A). Install bearing (5) in the governor housing to dimension (X) or 2.385 .005 in. (60.58 0.13 mm) from bearing (6). Install plug (7) in the governor housing. 4. Use tooling (A) to install the seal in governor housing (8). Install the seal with the lip of the seal toward the inside.5. Install torque spring assembly (9) on the governor housing. Install the lock and bolts that hold it. See RACK SETTING INFORMATION for the correct adjustment of the torque spring assembly. 6. Put lever assembly (11) in position in the governor housing. Install shaft (10) in the housing through the lever. Install the lock and bolt that hold the lever to the shaft. 7. Install speed limiter plunger (14), spring (13) and plug (12) in the governor housing. 8. Install O-ring seal (17) on sleeve (18).9. Install piston (16) and the sleeve in cylinder (15). 10. Put weight assembly (19) on cylinder (15). Install the ring that holds the weight assembly on the cylinder. 11. Install valve (21) in piston (16).12. Install bearing and washers (22) on sleeve (20). Install the ring that holds the washers and bearing on the sleeve.13. Install the sleeve assembly on valve (21). 14. Install bolt (23) in seat (24). Install the washers and spring in the seat.15. Put the seat in position on