101602-2643 ZEXEL 9 400 614 785 BOSCH INJECTION-PUMP ASSEMBLY 9400614785 1016022643 220801563a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 785 9400614785

ZEXEL 101602-2643 1016022643

HINO 220801563A 220801563a

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101472-0061 as _

Cross reference number

BOSCH 9 400 614 785 9400614785

ZEXEL 101602-2643 1016022643

HINO 220801563A 220801563a

Zexel num

Bosch num

Firm num

Name

101602-2643

9 400 614 785

220801563A HINO

INJECTION-PUMP ASSEMBLY
W06D 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

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

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 3.1 3.05 3.15

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Rack position (8.1)

Vist V 2.38 2.38 2.38

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 49.7 47.7 51.7

Max. variation between cylinders % 0 -3 3

Basic *

Injection quantity adjustment_02

Rack position (5.8)

Vist V 2.8 2.7 2.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=16mm bb=1mm
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a=19deg+-5deg b=29deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(70deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Installation Procedure
Table 1
Required Parts
Item Qty Part Number Description
1 1 285-1163 Cable
2 1 493-6051 Cover
3 1 5P-7958 Cable Splice Sleeve
Prepare the machine for maintenance. Refer to Operation and Maintenance Manual, "Prepare the Machine for Maintenance".
Illustration 1 g06048101
View of the Diesel Exhaust Fluid (DEF) tank
(A) Bolt
(1) 285-1163 Cable
Remove and retain bolt (A) that secures the cover to the fuel tank.
Secure cable (1) around bolt (A) and reinstall bolt (A).
Illustration 2 g06048083
View of the Diesel Exhaust Fluid (DEF) tank
(1) 285-1163 Cable
(2) 493-6051 Cover
(3) 5P-7958 Cable Splice Sleeve
Slide cover (2) over the fill tube on the tank.Insert the loose end of cable (1) through the hole of cover (2).Secure cable (1) with cable splice sleeve (3).