Information injection-pump assembly
BOSCH
9 400 612 292
9400612292
ZEXEL
108822-3322
1088223322
HINO
220402102A
220402102a
Rating:
Service parts 108822-3322 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
11.
Nozzle and Holder
23600-3040A
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
108822-3322
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 292
9400612292
ZEXEL
108822-3322
1088223322
HINO
220402102A
220402102a
Zexel num
Bosch num
Firm num
Name
9 400 612 292
220402102A HINO
INJECTION-PUMP ASSEMBLY
F21C-F * K 14CK TICS HD-TI8M TICS
F21C-F * K 14CK TICS HD-TI8M 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
134424-4120
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.
407980-2
24*
Digi switch no.
41
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
7.2
7.17
7.23
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
11.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
107
104
110
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.7+-0.5
Pump speed
r/min
435
435
435
Average injection quantity
mm3/st.
13.3
12.3
14.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
7.1+-0.0
3
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(11.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
107
105
109
Basic
*
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
105.5
99.5
111.5
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
0000001601
Pre-stroke
mm
7.2
7.17
7.23
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
11.5
11
12
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.2
3.15
3.25
Output voltage
V
2.95
2.94
2.96
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
7.2
7.17
7.23
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
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)Set the stop lever before governor adjustment. [When setting the stop lever after governor adjustment, confirm that R = R1 + 1 (point B) can be obtained at the full setting.]
(4)Stop lever's normal position setting: RA
(5)Damper spring setting: DL
----------
T1=AG89 RA=(17)mm DL=7.4-0.2mm
----------
----------
T1=AG89 RA=(17)mm DL=7.4-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=94mm
----------
a=15.5deg+-5deg b=39deg+-3deg
----------
aa=94mm
----------
a=15.5deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Stopper bolt setting
(3)Speed = aa, rack position = CC
(4)Stopper bolt setting
(5)Use the hole above R = dd
----------
aa=0r/min bb=(17)mm cc=0.5+-0.3mm dd=35mm
----------
a=35deg+-5deg b=23deg+-5deg
----------
aa=0r/min bb=(17)mm cc=0.5+-0.3mm dd=35mm
----------
a=35deg+-5deg b=23deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.:-
(7)Pre-stroke: aa
----------
aa=7.2+-0.03mm
----------
a=(80deg)
----------
aa=7.2+-0.03mm
----------
a=(80deg)
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=1100r/min Ra=R1(11.8)+1mm
----------
----------
N1=1100r/min Ra=R1(11.8)+1mm
----------
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
Diesel exhaust fluid may begin to leak from the 421-6842 Control Valve As due to breakage of the valve stem.
Illustration 1 g03774942
Location of valve assemblySolution
In order to fix the valve assembly leakage, rework the hose installation and replace the valve if the valve stem has broken. Refer to the following ""Rework Procedure"".Required Parts
Table 1
Required Parts
Item Qty Part Number Description
1 1 421-6842 Control Valve As (1)
2 2 132-5789 Clip
3 2 3S-2093 Cable Strap
( 1 ) If neededRework Procedure
Check the diesel exhaust fluid leakage from valve assembly (1). If there is no leakage, skip Steps 2 and 3. If there is leakage present, perform the following Steps 1 through 6.
Illustration 2 g03774935
(1) 421-6842 Control Valve As (4) 8M-2773 Clip or 067-2551 Clip (depending on sales model) (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (7) 6S-8620 Hose Clamp
Remove two clips (4), two bolts (5), and two washers (6) .Note: Retain the bolts and washers for reuse when installing the new clips.
Remove valve assembly (1) and two clamps (7) .
Attach the two hoses to new valve assembly (1). Secure by tightening the clamps to a torque of 1.4 0.3 N m (12.4 2.7 lb in).Note: Insert the hose up to the root of the valve tube.Note: Place the clamp on the straight portion of the hose by the bead of the valve tube.
Illustration 3 g03774975
(1) 421-6842 Control Valve As (3) 3S-2093 Cable Strap (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (A) 90 degree angle
Install two new clips (2) and secure with bolts (5) and washers (6) on the mounting boss.
Tighten bolts (5) to a torque of 55 10 N m (40.6 7.8 lb ft).
Secure both hoses to clips (2) using straps (3). Ensure that both hoses are straight against valve assembly (1) .Note: The clips must be attached at a 90 degree angle to the valve assembly. Refer to Illustration 3.Note: Do not apply a twisting force on the valve assembly when securing the hoses.Note: Do not deform the hoses when tightening the straps.
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
Diesel exhaust fluid may begin to leak from the 421-6842 Control Valve As due to breakage of the valve stem.
Illustration 1 g03774942
Location of valve assemblySolution
In order to fix the valve assembly leakage, rework the hose installation and replace the valve if the valve stem has broken. Refer to the following ""Rework Procedure"".Required Parts
Table 1
Required Parts
Item Qty Part Number Description
1 1 421-6842 Control Valve As (1)
2 2 132-5789 Clip
3 2 3S-2093 Cable Strap
( 1 ) If neededRework Procedure
Check the diesel exhaust fluid leakage from valve assembly (1). If there is no leakage, skip Steps 2 and 3. If there is leakage present, perform the following Steps 1 through 6.
Illustration 2 g03774935
(1) 421-6842 Control Valve As (4) 8M-2773 Clip or 067-2551 Clip (depending on sales model) (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (7) 6S-8620 Hose Clamp
Remove two clips (4), two bolts (5), and two washers (6) .Note: Retain the bolts and washers for reuse when installing the new clips.
Remove valve assembly (1) and two clamps (7) .
Attach the two hoses to new valve assembly (1). Secure by tightening the clamps to a torque of 1.4 0.3 N m (12.4 2.7 lb in).Note: Insert the hose up to the root of the valve tube.Note: Place the clamp on the straight portion of the hose by the bead of the valve tube.
Illustration 3 g03774975
(1) 421-6842 Control Valve As (3) 3S-2093 Cable Strap (5) 8T-4137 Bolt (6) 8T-4121 Hard Washer (A) 90 degree angle
Install two new clips (2) and secure with bolts (5) and washers (6) on the mounting boss.
Tighten bolts (5) to a torque of 55 10 N m (40.6 7.8 lb ft).
Secure both hoses to clips (2) using straps (3). Ensure that both hoses are straight against valve assembly (1) .Note: The clips must be attached at a 90 degree angle to the valve assembly. Refer to Illustration 3.Note: Do not apply a twisting force on the valve assembly when securing the hoses.Note: Do not deform the hoses when tightening the straps.