Information injection-pump assembly
BOSCH
9 400 613 659
9400613659
ZEXEL
101401-2271
1014012271
HINO
220007690A
220007690a
Rating:
Service parts 101401-2271 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001981A
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 659
9400613659
ZEXEL
101401-2271
1014012271
HINO
220007690A
220007690a
Zexel num
Bosch num
Firm num
Name
101401-2271
9 400 613 659
220007690A HINO
INJECTION-PUMP ASSEMBLY
W04C-TF * K
W04C-TF * 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
4.3
4.27
4.33
Rack position
Point A R=A
Point A R=A
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
11.3
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83
81
85
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+-0.5
Pump speed
r/min
315
315
315
Average injection quantity
mm3/st.
9
7.5
10.5
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(11.3)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83
82
84
Basic
*
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
91
87
95
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-(1.2)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
37.6
33.6
41.6
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
11.2
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
49.5
47.5
51.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
E
Rack position
R2(R1-0.
3)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
65.2
61.2
69.2
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_08
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
109
99
119
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
11.2
Boost pressure
kPa
2
2
4
Boost pressure
mmHg
15
15
30
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R1+1.1
Boost pressure
kPa
9.3
9.3
9.3
Boost pressure
mmHg
70
70
70
Timer adjustment
Pump speed
r/min
900
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_02
Pump speed
r/min
(1000)
Advance angle
deg.
1.25
0.65
1.25
Load
4/4
Timer adjustment_03
Pump speed
r/min
1200
Advance angle
deg.
1.25
0.65
1.25
Load
3/4
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
4.2
4.8
Load
4/4
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)Boost compensator stroke: BCL
(4)Idle increase set point (air cylinder's negative pressure supply: P1)
----------
T1=D20 BCL=(1.2)+-0.1mm P1=392+98kPa(4+1kgf/cm2)
----------
----------
T1=D20 BCL=(1.2)+-0.1mm P1=392+98kPa(4+1kgf/cm2)
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=22.5deg+-5deg b=39deg+-3deg
----------
----------
a=22.5deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=40deg+-5deg
----------
----------
a=40deg+-5deg b=40deg+-5deg
0000001501 AIR CYLINDER
(A): Speed lever
(B): Set bolt
(C): air cylinder
(D): nut
(E): fix
1. Air cylinder adjustment procedure
(1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L1.
(2)Set the speed to N1 and supply positive pressure P1 to the air cylinder (C).
(3)Gradually push set bolt (B) out (approximately L2) and tighten nut (D) where the speed is N2 and the rack position is Ra.
(4)Apply positive pressure P1 several times.
(5)Confirm that the lever returns to the idle position at positive pressure P2.
(6)Also, confirm that the rack position is Rb at air pressure P1.
----------
L1=(9)mm L2=(6)mm Ra=8.5~8.7mm Rb=8.5~8.7mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
----------
L1=(9)mm L2=(6)mm Ra=8.5~8.7mm Rb=8.5~8.7mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------
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:
Before any service work is to be done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engines. Service work can be done with it installed on engine. 1. Remove the flange (1) and flange assembly (2) from the cover (3).2. Remove the cover from the pump housing by removing seven bolts. 3. Remove the solenoid (4) from the cover.4. Remove cover (6).5. Remove two bolts (5) that hold the cover to the shutoff housing. 6. Remove the cover from the shutoff housing (7). 7. Remove the lever (10) from the shaft (11).8. Remove the shaft (9) from the shutoff housing.9. Remove the lever (8) from the shaft (11).10. Remove the shaft (11) from the shutoff housing.11. Remove the seal (12) from the shutoff housing.Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be .039 in. (1.0 mm) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Install the shaft (3) in the shutoff housing.3. Install the lever (5) on the shaft (3).4. Install shaft (2) in the shutoff housing.5. Install the lever (4) on shaft (3). 6. Put the cover (6) in position on the shutoff housing and install two bolts that hold the cover to the housing. 7. Install the cover (8).8. Install the solenoid (7) on the cover.9. Install the cover (6) on the pump housing.10. Install the flange assembly and the flange on the cover.
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101401-2271
9 400 613 659
220007690A
INJECTION-PUMP ASSEMBLY
W04C-TF
W04C-TF