Information injection-pump assembly
BOSCH
9 400 613 655
9400613655
ZEXEL
101401-2221
1014012221
HINO
220006460A
220006460a
Rating:
Service parts 101401-2221 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001981A
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 655
9400613655
ZEXEL
101401-2221
1014012221
HINO
220006460A
220006460a
Zexel num
Bosch num
Firm num
Name
101401-2221
9 400 613 655
220006460A HINO
INJECTION-PUMP ASSEMBLY
W04C-TD * K
W04C-TD * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
4.4
4.37
4.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
98.3
96.3
100.3
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.2+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
21
19.5
22.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.9)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
98.3
97.3
99.3
Basic
*
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.15
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
99.7
95.7
103.7
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-1)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
73.8
69.8
77.8
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_06
Adjusting point
D
Rack position
(R1-0.75
)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
81.9
77.9
85.9
Fixing the lever
*
Boost pressure
kPa
30.7
30.7
Boost pressure
mmHg
230
230
Injection quantity adjustment_07
Adjusting point
E
Rack position
-
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
55.9
51.9
59.9
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_08
Adjusting point
F
Rack position
R2-0.9
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
48
44
52
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_09
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
110
120
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R2-0.9
Boost pressure
kPa
6.7
6.7
9.4
Boost pressure
mmHg
50
50
70
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R2(R1-1)
Boost pressure
kPa
17.3
17.3
17.3
Boost pressure
mmHg
130
130
130
Timer adjustment
Pump speed
r/min
1350--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
3.5
3.2
3.8
Remarks
Finish
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
(4)Boost compensator stroke: BCL
----------
T1=D36 BCL=0.9+-0.1mm
----------
----------
T1=D36 BCL=0.9+-0.1mm
----------
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=34deg+-5deg b=39deg+-3deg
----------
aa=50mm
----------
a=34deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=35mm
----------
a=35deg+-5deg b=(40deg)+-5deg
----------
aa=35mm
----------
a=35deg+-5deg b=(40deg)+-5deg
0000001501 TAMPER PROOF
1. Method for setting tamperproof proofing
(1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra.
(2)At pump speed N1, push in the screw (A) until the rack position is Rb.
(3)Temporarily caulk using the tip of a screwdriver
(4)Confirm that the rack at that time is at Rc.
(5)Lock using setscrew (B). (Tightening torque = T)
(6)Next, coat (C) with adhesive and then pressfit.
(7)Then, readjust the full rack position using the load lever.
----------
N1=1600r/min Ra=(1)mm Rb=R1(11.9)+0.35mm Rc=R1(11.9)+0.35mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)
----------
N1=1600r/min Ra=(1)mm Rb=R1(11.9)+0.35mm Rc=R1(11.9)+0.35mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)
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)
----------
----------
a=(70deg)
Information:
If fuel line clamps are not installed in their exact location, vibration can cause the fuel lines to break and cause possible personal injury, or damage to the machine.
1. Disconnect front fuel injection lines (1), disconnect middle fuel injection lines (2) and rear fuel injection lines (3) from the fuel injection pump and the cylinder head assembly.2. Remove fuel injection lines (1), (2) and (3). Put caps or plugs on all fuel line connections to keep foreign material out of the fuel system.3. If a separation of the fuel lines has to be made, make sure the exact location of the clamps are marked for assembly purposes. Remove the clamps and make a separation of the fuel lines. The following steps are for the installation of the fuel injection lines.4. Remove the caps or plugs for the fuel injection line connections.5. If removed, connect the fuel lines with the clamps. Make sure the clamps are installed back in their correct location. Use Tool (A) to tighten the clamp bolts to a torque of 2.3 N m (20 lb in). For more information, see Specifications Manual SENR6470, of Testing & Adjusting Manual SENR6471.6. Install front fuel injection lines (1) on the fuel injection pump and cylinder head assembly.7 Install middle fuel injection lines (2) on the fuel injection pump and the cylinder head assembly.8. Install rear fuel injection lines (3) on the fuel injection pump and the cylinder head assembly.9. Tighten the fuel injection line nuts to a torque of 40 7 N m (30 5 lb ft).
Have questions with 101401-2221?
Group cross 101401-2221 ZEXEL
Hino
Hino
Hino
101401-2221
9 400 613 655
220006460A
INJECTION-PUMP ASSEMBLY
W04C-TD
W04C-TD