101402-2390 ZEXEL 9 400 613 197 BOSCH INJECTION-PUMP ASSEMBLY 9400613197 1014022390 220206300a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 197 9400613197

ZEXEL 101402-2390 1014022390

HINO 220206300A 220206300a

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Service parts 101402-2390 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9550

3. GOVERNOR 105400-9401

4. SUPPLY PUMP 105220-6580

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-9520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8610

11. Nozzle and Holder 236003420A

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105031-7310

14. NOZZLE

15. NOZZLE SET 105019-2620

Include in #1:

101402-2390 as INJECTION-PUMP ASSEMBLY

101603-2531 as _

Cross reference number

BOSCH 9 400 613 197 9400613197

ZEXEL 101402-2390 1014022390

HINO 220206300A 220206300a

Zexel num

Bosch num

Firm num

Name

101402-2390
101402-2391

9 400 613 197

220206300A HINO

INJECTION-PUMP ASSEMBLY
W04D * K 14BD INJECTION PUMP ASSY PE4AD PE

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 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.8 4.75 4.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75 73 77

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.3+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 11.5 10 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 10.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=12 N1=900r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=80mm
----------
a=30deg+-5deg b=56deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=6.1mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-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)

Information:

2. Remove the two bolts (1) from transfer pump, and pull the pump out of accessory drive housing.3. Remove the four bolts and lock from retainer (3). Remove the retainer.4. Remove the drive gear (2). 5. Remove the two bolts, locks, and plate (5).6. Remove the variable timing unit (4) from the accessory drive housing.Install Variable Timing Unit
1. Put the variable timing unit (1) in position in the accessory drive housing.2. Install the retaining plate, locks, and two bolts.3. Install the drive gear, retainer, lock, and four bolts. Do not tighten the four bolts.4. Make an adjustment to the timing of the camshaft for the fuel injection pump. See FUEL INJECTION PUMP CAMSHAFT TIMING in TESTING AND ADJUSTING. 5. Install the cover (4) on timing gear housing.6. Put the transfer pump (3) in position on the accessory drive housing, and install the two bolts (2).7. Check to be sure all timing pins and bolts have been removed from their timing holes, and are installed in their storage positions.Disassemble Variable Timing Unit
start by: a) remove variable timing unit 1. Push down on retainer (1), and remove the pin (2).2. Remove the retainer and spring. 3. Use a hammer and punch to remove the dowels (4). Remove the two weights.4. Remove the piston and rod assembly (5) from shaft assembly (3).5. Remove the pins from nut and rod.6. Remove the rod, nut, spring, and valve from the piston assembly.Assemble Variable Timing Unit
1. Install the valve, spring, and nut on the piston assembly. Turn the nut until the distance (X) between bottom face of nut and the piston is 1.760 in. (44.7 mm). Drill a .095 .002 in. (2.41 0.05 mm) diameter hole through the nut and the threads of piston assembly. Install the pin in nut. 1. Install the rod tight against the nut. Take a measurement .156 in. (3.96 mm) from top face of nut, and put a mark at this location on rod. Drill a .095 .0.05 mm) diameter hole (1) through the rod and piston assembly at this location. Install the pin in rod.3. Install the piston and rod assembly in the shaft assembly. Install the spring, retainer, and pin in shaft assembly.4. Install the weights and dowels. Use a hammer and punch to fasten both ends of the dowels in place. Both weights must move freely after the dowels have been fastened in place.end by: a) install variable timing unit