Rating:
Information injection-pump assembly
BOSCH
9 400 613 314
9400613314
ZEXEL
107691-3660
1076913660
HINO
220402311A
220402311a
Service parts 107691-3660 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
107691-3660
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 613 314
9400613314
ZEXEL
107691-3660
1076913660
HINO
220402311A
220402311a
Zexel num
Bosch num
Firm num
Name
9 400 613 314
220402311A HINO
INJECTION-PUMP ASSEMBLY
J08C-TT * K 14CG TICS MD-TI6 TICS
J08C-TT * K 14CG TICS MD-TI6 TICS
9 400 613 314
220402312A HINO
INJECTION-PUMP ASSEMBLY
J08C-TT A * K 14CG TICS MD-TI6 TICS
J08C-TT A * 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.
407980-2
24*
Digi switch no.
17
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
12.6
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
115.5
112.5
118.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.2+-0.5
Pump speed
r/min
440
440
440
Each cylinder's injection qty
mm3/st.
13.5
12.15
14.85
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
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(12.6)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
115.5
113.5
117.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
54
54
Boost pressure
mmHg
405
405
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+2.15
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
126.5
120.5
132.5
Fixing the lever
*
Boost pressure
kPa
54
54
Boost pressure
mmHg
405
405
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-1.5
Boost pressure
kPa
21.3
20
22.6
Boost pressure
mmHg
160
150
170
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-1)
Boost pressure
kPa
40.7
40.7
40.7
Boost pressure
mmHg
305
305
305
Timer adjustment
Pump speed
r/min
(N1+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1(1130)
Advance angle
deg.
0
0
0
Remarks
Pointer stamping position
Pointer stamping position
Timer adjustment_03
Pump speed
r/min
N1(1130)
Advance angle
deg.
0
-0.3
0
Timer adjustment_04
Pump speed
r/min
(1265)
Advance angle
deg.
-1.5
-1.8
-1.2
Remarks
Finish
Finish
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
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
24
23.5
24.5
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
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)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at the full setting.
(4)Stop lever's normal position setting: RA
(5)Boost compensator stroke: BCL
----------
T1=AH03 Ra=R1+2.15mm RA=(18)mm BCL=1.5+-0.1mm
----------
----------
T1=AH03 Ra=R1+2.15mm RA=(18)mm BCL=1.5+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=44mm
----------
a=8.5deg+-5deg b=(39deg)+-3deg
----------
aa=44mm
----------
a=8.5deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
(2)Speed = bb, rack position = cc
(3)Use the hole above R = dd
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
a=15deg+-5deg b=35deg+-5deg
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=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=(30deg)
----------
aa=5.1+-0.03mm
----------
a=(30deg)
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 clockwise (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 counterclockwise 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
G:Red paint
H:Pump end face
P/N: part number of suitable shim
(1)Threaded type rack block
(2)Welded type rack block
Rack sensor adjustment
1. Threaded type rack sensor (-5*20, P type, no TICS rack limit).
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the pump lever.
(3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1.
(4)Fix using the nut (F).
(5)Affix the caution plate to the upper part of the joint (B).
(6)Apply (G) at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the end surface of the pump (H) and the joint (B)
2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads.
Screw in to the end from (the position where the bobbin (A) is rotated 9 turns).
Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.6)+2.15mm N1=1250r/min V1=3+-0.01V
----------
----------
Ra=R1(12.6)+2.15mm N1=1250r/min V1=3+-0.01V
----------
0000002301 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Lever
1. Aneroid compensator unit adjustment
(1)Screw in (A) to obtain L1.
(2)Select C so that dimension L2 can be obtained.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Set to full boost.
(3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.15)mm Rb=R3-0.75mm Rc=(R3-0.9)mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) P3=65.7+-1.3kPa(493+-10mmHg) Q1=126.5+-6cm3/1000st Q2=114.5+-10cm3/1000st Q3=112.5+-10cm3/1000st
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.15)mm Rb=R3-0.75mm Rc=(R3-0.9)mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) P3=65.7+-1.3kPa(493+-10mmHg) Q1=126.5+-6cm3/1000st Q2=114.5+-10cm3/1000st Q3=112.5+-10cm3/1000st