101401-2213 ZEXEL 9 400 613 654 BOSCH INJECTION-PUMP ASSEMBLY 9400613654 1014012213 220006301b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 654 9400613654

ZEXEL 101401-2213 1014012213

HINO 220006301B 220006301b

Service parts 101401-2213 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9630

3. GOVERNOR 105921-4590

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0711

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5151

11. Nozzle and Holder 236002161A

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105041-5160

14. NOZZLE

15. NOZZLE SET

Include in #1:

101401-2213 as INJECTION-PUMP ASSEMBLY

108622-3591 as _

108622-3592

Cross reference number

BOSCH 9 400 613 654 9400613654

ZEXEL 101401-2213 1014012213

HINO 220006301B 220006301b

Zexel num

Bosch num

Firm num

Name

101401-2213

9 400 613 654

220006301B HINO

INJECTION-PUMP ASSEMBLY
W04C-TG * 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 12.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78 76 80

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 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.5 7 10

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(12.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78 77 79

Basic *

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.65

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 83.9 79.9 87.9

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 61.6 57.6 65.6

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_06

Adjusting point D

Rack position R2(12)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 49.7 47.7 51.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point E

Rack position R1-0.4

Pump speed r/min 1280 1280 1280

Average injection quantity mm3/st. 80.4 76.4 84.4

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 107 107 117

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2(12)

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R1+1.3

Boost pressure kPa 12.7 12.7 12.7

Boost pressure mmHg 95 95 95

Timer adjustment

Pump speed r/min 1010--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 960

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 1060

Advance angle deg. 1.5 1.2 1.8

Load 4/4

Timer adjustment_04

Pump speed r/min 1280

Advance angle deg. 1.8

Load 3/4

Timer adjustment_05

Pump speed r/min 1600

Advance angle deg. 4.5 4.2 4.8

Load 4/4

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
----------
T1=F13 BCL=(1.5)+-0.1mm
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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=13deg+-5deg b=40deg+-5deg

0000001501 ACTUATOR

(a) Screw (B) Nut (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Position the control lever (d) in the idling position. (2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator. (5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0. (7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=10.6~10.9mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
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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)