101601-5043 ZEXEL 9 400 614 596 BOSCH INJECTION-PUMP ASSEMBLY 9400614596 1016015043 220801311a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 596 9400614596

ZEXEL 101601-5043 1016015043

HINO 220801311A 220801311a

Include in #1:

106682-9192 as _

Cross reference number

BOSCH 9 400 614 596 9400614596

ZEXEL 101601-5043 1016015043

HINO 220801311A 220801311a

Zexel num

Bosch num

Firm num

Name

101601-5043

9 400 614 596

220801311A HINO

INJECTION-PUMP ASSEMBLY
W06D 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 131424-5720

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 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 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 8.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 47.2 51.2

Max. variation between cylinders % 0 -3.5 3.5

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 250 250 250

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 48.2 50.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 45 43 47

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.2

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 55.7 53.7 57.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.15

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 38.7 36.7 40.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 13.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 105

Fixing the lever *

Rack limit *

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. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=90
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=33deg+-3deg b=34deg+-5deg

Stop lever angle

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

0000001501 ACTUATOR

(a) actuator (b) Speed lever (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Apply negative pressure P1 to the actuator (a) and confirm that the stroke is approximately L1. (2)Set the speed lever (b) at the idling position (N = 0). (3)Set temporarily so that the clearance from the set bolt is approximately L2. (4)Set the pump speed at N1 and apply negative pressure P2. (5)Adjust set bolt (c) so that the rack position is R1 to R2. (6)Set the pump speed at N2 and apply negative pressure P3. (7)At this time, confirm that the speed lever (b) moves smoothly and that the rack position becomes R1 to R2.
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L1=10mm L2=2mm P1=66.7kPa(500mmHg) P2=66.7kPa(500mmHg) P3=66.7kPa(500mmHg) N1=250r/min N2=250r/min R1=8.4mm R2=8.7mm
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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)