101601-5670 ZEXEL 9 400 614 623 BOSCH INJECTION-PUMP ASSEMBLY 9400614623 1016015670 220006440a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 623 9400614623

ZEXEL 101601-5670 1016015670

HINO 220006440A 220006440a

Service parts 101601-5670 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3831

3. GOVERNOR 105921-4012

4. SUPPLY PUMP 105210-4990

5. AUTOM. ADVANCE MECHANIS 105672-0120

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6280

11. Nozzle and Holder 23600-2133

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

13. NOZZLE-HOLDER 105030-4300

14. NOZZLE

105015-8590

15. NOZZLE SET

Include in #1:

101601-5670 as INJECTION-PUMP ASSEMBLY

104303-2710 as _

Cross reference number

BOSCH 9 400 614 623 9400614623

ZEXEL 101601-5670 1016015670

HINO 220006440A 220006440a

Zexel num

Bosch num

Firm num

Name

101601-5670
101601-5671

9 400 614 623

220006440A HINO

INJECTION-PUMP ASSEMBLY
H07D-A 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

Bosch type code DN12SD12T-1

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 3.8 3.77 3.83

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 11.5

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.6 76 79.2

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 9+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 16.9 15.9 17.9

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.6 76.6 78.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.5

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88.9 84.9 92.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 64.2 60.2 68.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 87.4 83.4 91.4

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 925--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 875

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (920--)

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 1175+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1400+50

Advance angle deg. 5.5 5.2 5.8

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
----------
T1=F80
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=37deg+-3deg b=40deg+-5deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Use the hole at R = aa (2)Set the stopper screw. (After setting, apply red paint.)
----------
aa=35mm
----------
a=14.5deg+-5deg b=(31deg)+-5deg

0000001501 LEVER

(N) Engine normal (pump normal) (S) Engine stop (A) stopper screw (B) Stop direction (perpendicular) Stop lever adjusting procedure (1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above. (2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra. (3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc) (4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc. (5)After adjustment, apply red paint.
----------
Na=1530r/min Ra=5.9mm Rb=1.5mm Nb=1.5 Rc=- Nc=250r/min
----------
ra=37mm a=14.5deg+-5deg b=(31deg)+-5deg