101601-5484 ZEXEL F 01G 09U 02U BOSCH INJECTION-PUMP ASSEMBLY f01g09u02u 1016015484 220006231a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 02U f01g09u02u

ZEXEL 101601-5484 1016015484

HINO 220006231A 220006231a

Service parts 101601-5484 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9480

3. GOVERNOR 105921-3424

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0611

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder 23600-2142A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101601-5484 as INJECTION-PUMP ASSEMBLY

106682-9540 as _

Cross reference number

BOSCH F 01G 09U 02U f01g09u02u

ZEXEL 101601-5484 1016015484

HINO 220006231A 220006231a

Zexel num

Bosch num

Firm num

Name

101601-5484
101601-5485

F 01G 09U 02U

220006231A 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 105780-8210

Nozzle 105780-0070

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 1-4-2-6- 3-5

Pre-stroke mm 3.45 3.42 3.48

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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.9 64.9 68.9

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 9.5+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 18.5 17.5 19.5

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.9 65.9 67.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 68.9 64.9 72.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 57.9 53.9 61.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 127.5 127.5 137.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 960--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 910

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min 1010

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 1210

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1510

Advance angle deg. 6 5.7 6.3

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
----------
T1=E34
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=(41deg)+-3deg b=46deg+-5deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Pump normal (2)Set the stopper bolt at rack = aa (at shipping). (3)After setting, apply red paint. (4)At speed lever full position and pump speed bb, set the stopper screw at rack position cc (non-injection rack position). (5)Confirm non-injection with the speed lever in the idle position at speed = dd. (6)With the speed lever in the idle position at speed = ee, operate the stop lever 2 or 3 times and confirm that the rack does not stick. (7)After adjustment, apply red paint.
----------
aa=15+-0.1mm bb=1500r/min cc=6.6-0.5mm dd=250r/min ee=0r/min
----------
a=(35deg) b=40deg+-5deg c=(26deg)+-5deg

Timing setting

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

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