101401-2282 ZEXEL 9 400 613 660 BOSCH INJECTION-PUMP ASSEMBLY 9400613660 1014012282 220203961a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 660 9400613660

ZEXEL 101401-2282 1014012282

HINO 220203961A 220203961a

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Buy INJECTION-PUMP ASSEMBLY 101401-2282 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-2282 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9831

3. GOVERNOR 105401-0551

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0851

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4320

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101401-2282 as INJECTION-PUMP ASSEMBLY

107491-3061 as _

Cross reference number

BOSCH 9 400 613 660 9400613660

ZEXEL 101401-2282 1014012282

HINO 220203961A 220203961a

Zexel num

Bosch num

Firm num

Name

101401-2282

9 400 613 660

220203961A HINO

INJECTION-PUMP ASSEMBLY
W04C-T * 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 1-3-4-2

Pre-stroke mm 3.2 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point A

Rack position 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 88.2 86.2 90.2

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8.4 6.9 9.9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-0.75

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(10.8)

Boost pressure kPa 34.7 34.7 34.7

Boost pressure mmHg 260 260 260

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.5 2 3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 3.5 3.5 3.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Main spring setting (4)Set idle sub-spring (5)Boost compensator stroke (at N = N1)
----------
K=10 N1=650r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(12deg)+-5deg b=(26deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

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)

Information:

start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove the bolts (1) that hold the governor housing (2) to the fuel injection pump housing.3. Remove the governor housing (2). 4. Remove two springs (4) and the seat (5) from the governor housing.5. Remove the seat (7) from the shaft.6. Remove the spring (6) from the shaft.7. Remove the cover (3) from the pump housing. 8. Remove the shaft (8) and the lever (9) from the pump housing. 9. Remove the thrust collar (11) from the shaft.10. Remove the cover (10) from the pump housing. 11. Loosen the two bolts (13) that hold the torque spring assembly (12) and remove it from the pump housing. 12. Remove the pin (15) from the pump housing.13. Remove the screw (14) and the nut (16) from the pump housing.14. Remove the ring that holds the lever and remove the lever (18) from the dowel (17).15. Remove the dowel (17) from the pump housing. Dowel does not need to be removed unless camshaft is to be removed.
Pull on the shield only a small amount in each location so it will not have distortion or damage. A damaged shield must be replaced.
16. Remove the shield (19) from the camshaft with tool (B). 17. Install the timing pin (C) to hold the camshaft.18. Remove the bolts (20) that hold the flyweight assembly to the camshaft. 19. Remove the flyweight assembly (21) from the camshaft.20. Remove the timing pin (C) from the pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on the bracket assembly (A).2. Install the timing pin (B) to hold the camshaft.3. Put the flyweight assembly (1) in position on the camshaft. Be sure the pin that holds the shaft (2) is in position on the back of the flyweight assembly.4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 10 2 lb. ft. (1.38 0.28 mkg).5. Remove the timing pin (B). 6. Put the shield (3) in position over the flyweights. 7. Use the driver (C) to install the shield the remainder of the way on to the camshaft. 8. Put a new O-ring seal on the dowel (4) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing. 9. Put the lever (8) on the dowel (4) and install the ring that holds it on the dowel.10. Install the screw (6) and the nut (7) in the pump housing.11. Install the pin (5) in the pump housing. 12. Put the torque spring assembly (10) in position on the housing and tighten the two bolts (11) that hold it to the housing.13. Install the cover (9) on the pump housing. 14. Put the thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire