101601-5921 ZEXEL F 019 Z20 458 BOSCH INJECTION-PUMP ASSEMBLY f019z20458 1016015921 220007910b


 

Information injection-pump assembly

BOSCH F 019 Z20 458 f019z20458
ZEXEL 101601-5921 1016015921
HINO 220007910B 220007910b
101601-5921 INJECTION-PUMP ASSEMBLY
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Service parts 101601-5921 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6030
3. GOVERNOR 105931-9180
4. SUPPLY PUMP 105210-5210
5. AUTOM. ADVANCE MECHANIS 105672-5130
6. COUPLING PLATE 105662-1310
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6593
11. Nozzle and Holder 23600-2373A
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105030-3431
14. NOZZLE 105015-9200
15. NOZZLE SET

Include in #1:

101601-5921 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH F 019 Z20 458 f019z20458
ZEXEL 101601-5921 1016015921
HINO 220007910B 220007910b


Zexel num
Bosch num
Firm num
Name
101601-5921 
101601-5922 
F 019 Z20 458 
220007910B  HINO
INJECTION-PUMP ASSEMBLY
J08C * K 14BF PE6AD 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   131424-8320
Overflow valve opening pressure kPa   108 88 128
Overflow valve opening pressure kgf/cm2   1.1 0.9 1.3
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-4-2-6- 3-5
Pre-stroke mm   4.3 4.27 4.33
Beginning of injection position
Governor 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   12.4
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   85.1 83.5 86.7
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   9.5+-0.5
Pump speed r/min   250 250 250
Each cylinder's injection qty mm3/st.   15.4 14.4 16.4
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.4)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   85.1 84.1 86.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   89.3 85.3 93.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.55
Pump speed r/min   580 580 580
Average injection quantity mm3/st.   73.6 69.6 77.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   136 136 146
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.3
Load   1/4
Timer adjustment_03
Pump speed r/min   (1000)
Advance angle deg.   1.5 1.2 1.8
Load   4/4
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1240+50
Advance angle deg.   1.5 1.2 1.8
Load   4/4
Timer adjustment_05
Pump speed r/min   1450-50
Advance angle deg.   5 4.7 5.3
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5921
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G89
----------

Speed control lever angle

Test data 101601-5921
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=34deg+-5deg b=38deg+-3deg

Stop lever angle

Test data 101601-5921
N:Pump normal S:Stop the pump.
----------

----------
a=28deg+-5deg b=40deg+-5deg

Timing setting

Test data 101601-5921
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)




Information:

New Dipsticks With Full Range Readings
The new rear sump and front sump dipsticks are used with their respective oil pans. These oil pans are used in truck applications with set-back axles.The new dipsticks are different because they have a FULL RANGE zone versus other dipsticks that have the traditional FULL mark. These dipsticks are used for truck applications with various angles and slants of engine installation (angle = front to back tilt, slant = sideways tilt).Calibration
Use the following procedure to calibrate FULL RANGE dipsticks. A convenient time to calibrate the dipstick is at the first oil change.Refer to the PM Level 1 of the Maintenance Management Schedule of this publication for the proper oil change interval.To verify the "ADD" mark and establish the actual "FULL" mark, use the following procedure: Truck must be parked on a level surface.1. Operate the engine until it reaches normal operating temperature.2. Stop the engine. Drain the oil and change the oil filter.3. Fill the crankcase with 32 U.S. quarts (30.3 liters) of oil. Brakesaver models require 36 quarts (34 L). Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.4. Allow the oil to drain back to the sump for a minimum of five minutes.5. Remove the dipstick. The oil level should be at the ADD mark. If it is not, mark the actual level on the dipstick. This is now the correct ADD mark.6. Add an additional 4 U.S. quarts (3.8 liters) of oil to the sump. Allow enough time for the oil to drain into the sump. Again, check the level on the dipstick.7. This is the correct FULL mark in the FULL RANGE zone on the dipstick. If it is not, mark the new FULL level on the dipstick. Remote mounted or auxiliary filters require additional oil also. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.8. Start the engine and operate until it reaches normal operating temperature. Stop the engine.9. Allow the oil to drain back to the sump for a minimum of 10 minutes.10. Remove the dipstick. The oil level should be near the FULL mark. If it is not, add oil until the level reaches the FULL mark on the dipstick.This procedure is correct for use with either the non-spacer plate oil pan or the spacer plate oil pan. Sump capacities and oil levels are the same for each oil pan.Any FULL RANGE dipstick for the 3406B Truck engine can be calibrated using this procedure.

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