101601-5802 ZEXEL 9 400 614 629 BOSCH INJECTION-PUMP ASSEMBLY 9400614629 1016015802 220007421a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 629 9400614629

ZEXEL 101601-5802 1016015802

HINO 220007421A 220007421a

Service parts 101601-5802 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-5310

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0241

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(220)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-0490

15. NOZZLE SET

Include in #1:

101601-5802 as INJECTION-PUMP ASSEMBLY

Include in #2:

104207-3002 as _

Cross reference number

BOSCH 9 400 614 629 9400614629

ZEXEL 101601-5802 1016015802

HINO 220007421A 220007421a

Zexel num

Bosch num

Firm num

Name

101601-5802

9 400 614 629

220007421A 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 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 42.4 46.4

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(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 43.4 45.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 43.5 41.5 45.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 44.1 42.1 46.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 36.2 34.2 38.2

Fixing the lever *

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL
----------
T1=93 RAL=[R1+0.2]+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-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)