101601-5467 ZEXEL 9 400 614 613 BOSCH INJECTION-PUMP ASSEMBLY 9400614613 1016015467 220006213a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 613 9400614613

ZEXEL 101601-5467 1016015467

HINO 220006213A 220006213a

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Buy INJECTION-PUMP ASSEMBLY 101601-5467 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5467 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9480

3. GOVERNOR 105921-4033

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0612

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101601-5467 as INJECTION-PUMP ASSEMBLY

106684-4241 as _

Cross reference number

BOSCH 9 400 614 613 9400614613

ZEXEL 101601-5467 1016015467

HINO 220006213A 220006213a

Zexel num

Bosch num

Firm num

Name

101601-5467

9 400 614 613

220006213A HINO

INJECTION-PUMP ASSEMBLY
W06E * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8210

Nozzle 105780-0070

Bosch type code DN12SD12T-1

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 1-4-2-6- 3-5

Pre-stroke mm 3.45 3.42 3.48

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 10.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63.7 61.7 65.7

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 9.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 17 16 18

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63.7 62.7 64.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 61.7 57.7 65.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 55.3 51.3 59.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 122 122 132

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 960--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1010

Advance angle deg. 1 0.7 1.3

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.7 1.3

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1510

Advance angle deg. 6 5.7 6.3

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
----------
T1=E73
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Engine normal (2)Set the stopper bolt at rack = aa (apply red paint after setting). (3)(At delivery)
----------
aa=17+-0.1mm
----------
a=40deg+-5deg b=40deg+-5deg c=(35deg)

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 timing gear cover
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
1. Loosen the bleed valves, and release the air pressure in the air tank. 2. Disconnect the lines from air compressor (1), and remove the air compressor. 3. Remove sleeve (2) from air compressor drive gear (3). 4. Remove the nut and washer that holds the air compressor drive gear to the air compressor. Use tooling (A) to remove air compressor drive gear (3) from the air compressor. 5. Remove nuts (4) and plate (5). Remove gear assembly (6) from the shaft. 6. If damaged, remove bearing (7) from gear assembly (6) with tooling (B) and a press. 7. Remove three nuts (8) and the washers from the adapter assembly studs.
Typical Example8. Remove adapter assembly (9) from the timing gear plate. 9. Remove shaft (10), O-ring seal (11) and sleeve (12) from the adapter assembly.Install Air Compressor And Accessory Drive
1. Install sleeve (12) into the adapter assembly.2. Install shaft (10) and O-ring seal (11) on the adapter assembly. 3. Put adapter assembly (9) in position on the timing gear plate. Fasten it with the three nuts and washers. 4. Install the bearing in gear assembly (6) with tooling (A) and a press. Install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the surface of the gear as shown. 5. Put gear assembly (6) in position on the shaft.6. Put plate (5) in position, and install three nuts (4) to hold it. 7. Put air compressor drive gear (3) in position on the air compressor shaft, and install the washer and nut (13). Tighten the nut to a torque of 200 25 N m (150 18 lb.ft.). Tap the gear with a hammer and tighten nut (13) again to a torque of 200 25 N m (150 18 lb.ft.). 8. Install sleeve (2) on gear (3). 9. Put a gasket in position on air compressor (1) and install the air compressor on the timing cover plate.End By:a. install timing gear cover