101601-5486 ZEXEL 9 400 614 615 BOSCH INJECTION-PUMP ASSEMBLY 9400614615 1016015486 220006232a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 615 9400614615

ZEXEL 101601-5486 1016015486

HINO 220006232A 220006232a

Service parts 101601-5486 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9730

3. GOVERNOR 105921-3424

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0612

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101601-5486 as INJECTION-PUMP ASSEMBLY

104303-2320 as _

Cross reference number

BOSCH 9 400 614 615 9400614615

ZEXEL 101601-5486 1016015486

HINO 220006232A 220006232a

Zexel num

Bosch num

Firm num

Name

101601-5486

9 400 614 615

220006232A HINO

INJECTION-PUMP ASSEMBLY
W06E-E * 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 1-4-2-6- 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 11.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.5 64.5 68.5

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. 16.4 15.4 17.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.5 65.5 67.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 63 59 67

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.45

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 46.8 42.8 50.8

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 124 124 134

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=H53
----------

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:Pump normal S:Engine stop (1)Engine normal (2)Rack position = aa (3)Set the stopper bolt (at shipping). (4)(Apply red paint after setting.) (5)At speed lever full position and pump speed bb, set the stopper screw at rack position cc (non-injection rack position). (6)Then confirm non-injection at speed lever idle speed = dd. (7)Set the idle speed at ee using the speed lever and move the stop lever 2 or 3 turns. Confirm that the rack is not pulled back. (8)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)