101401-2161 ZEXEL 9 400 613 649 BOSCH INJECTION-PUMP ASSEMBLY 9400613649 1014012161 220801470a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 649 9400613649

ZEXEL 101401-2161 1014012161

HINO 220801470A 220801470a

Service parts 101401-2161 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9490

3. GOVERNOR 105921-3190

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0601

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4320

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101401-2161 as INJECTION-PUMP ASSEMBLY

106873-3540 as _

Cross reference number

BOSCH 9 400 613 649 9400613649

ZEXEL 101401-2161 1014012161

HINO 220801470A 220801470a

Zexel num

Bosch num

Firm num

Name

101401-2161

9 400 613 649

220801470A HINO

INJECTION-PUMP ASSEMBLY
W04C-T * K

Calibration Data:

Adjustment conditions

Test oil
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 6-2-600

Overflow valve 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 10.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.1 73.1 77.1

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9 7.5 10.5

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(10.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.1 74.1 76.1

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.4)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 85.2 81.2 89.2

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 720 720 720

Average injection quantity mm3/st. 62.5 58.5 66.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point D

Rack position R2-1.2

Pump speed r/min 720 720 720

Average injection quantity mm3/st. 43.2 39.2 47.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.25

Pump speed r/min 1080 1080 1080

Average injection quantity mm3/st. 81.2 77.2 85.2

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_08

Adjusting point F

Rack position R1+0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 82.7 78.7 86.7

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_09

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110 120

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 720 720 720

Rack position R2-1.2

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 720 720 720

Rack position R2(R1-0. 25)

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

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)RACK LIMIT (4)Boost compensator stroke: BCL (5)Idle increase set point (air cylinder's negative pressure supply: P1)
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T1=D64 BCL=1.2+-0.1mm P1=392+98kPa(4+1kgf/cm2)
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=21.5deg+-5deg b=43deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=40deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

(A): Speed lever (B): Set bolt (C): air cylinder (D): nut (E): fix 1. Air cylinder adjustment procedure (1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L1. (2)Set the speed to N1 and supply positive pressure P1 to the air cylinder (C). (3)Gradually push set bolt (B) out (approximately L2) and tighten nut (D) where the speed is N2 and the rack position is Ra. (4)Apply positive pressure P1 several times. (5)Confirm that the lever returns to the idle position at positive pressure P2. (6)Also, confirm that the rack position is Rb at air pressure P1.
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L1=(9)mm L2=(6)mm Ra=7.5~7.7mm Rb=7.5~7.7mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(70deg)