101601-5372 ZEXEL 9 400 614 610 BOSCH INJECTION-PUMP ASSEMBLY 9400614610 1016015372 220005941a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 610 9400614610

ZEXEL 101601-5372 1016015372

HINO 220005941A 220005941a

Service parts 101601-5372 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-2781

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0581

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7570

11. Nozzle and Holder 236001843A

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/19.6(200)

13. NOZZLE-HOLDER 105030-4160

14. NOZZLE 105015-7580

15. NOZZLE SET

Include in #1:

101601-5372 as INJECTION-PUMP ASSEMBLY

106685-4340 as _

106685-4341

106685-4342

106685-4343

Cross reference number

BOSCH 9 400 614 610 9400614610

ZEXEL 101601-5372 1016015372

HINO 220005941A 220005941a

Zexel num

Bosch num

Firm num

Name

101601-5372

9 400 614 610

220005941A HINO

INJECTION-PUMP ASSEMBLY
W06E * 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 9.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 55.9 59.9

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 7.8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 5.3 3.8 6.8

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(9.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 56.9 58.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.6)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 63.9 59.9 67.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 40.3 36.3 44.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(9.6)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 63.7 59.7 67.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.45

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 39.9 35.9 43.9

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 14.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 108 108 118

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1330--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1280

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

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)RACK LIMIT
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T1=C02
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=37deg+-5deg b=(40deg)+-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=(5)mm L2=0.6++mm Ra=7.3+-0.1mm Rb=7.3+-0.1mm 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)