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


101401-2161 INJECTION-PUMP ASSEMBLY
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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

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

Test data 101401-2161
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)
----------
T1=D64 BCL=1.2+-0.1mm P1=392+98kPa(4+1kgf/cm2)
----------

Speed control lever angle

Test data 101401-2161
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=21.5deg+-5deg b=43deg+-3deg

Stop lever angle

Test data 101401-2161
N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

Test data 101401-2161
(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.
----------
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)
----------

Timing setting

Test data 101401-2161
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)




Have questions with 101401-2161?





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