Information injection-pump assembly
BOSCH
9 400 614 866
9400614866
ZEXEL
101602-5040
1016025040
HINO
220205910A
220205910a
Rating:
Service parts 101602-5040 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236003390A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 866
9400614866
ZEXEL
101602-5040
1016025040
HINO
220205910A
220205910a
Zexel num
Bosch num
Firm num
Name
101602-5040
9 400 614 866
220205910A HINO
INJECTION-PUMP ASSEMBLY
H07D K
H07D K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
4.8
4.77
4.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
115.5
114.5
116.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.1+-0.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
940
940
940
Average injection quantity
mm3/st.
16
15
17
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
135
145
Fixing the lever
*
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)The torque control spring does not operate.
(4)RACK LIMIT
(5)Set idle sub-spring
----------
K=8
----------
----------
K=8
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Stopper bolt setting
(3)When pump speed set at aa
(4)Set the pump speed at bb.
----------
aa=755r/min bb=935r/min
----------
a=6deg+-5deg b=13deg+-5deg c=1deg+-5deg
----------
aa=755r/min bb=935r/min
----------
a=6deg+-5deg b=13deg+-5deg c=1deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Rack position aa or less, pump speed bb
----------
aa=6.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=6.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
1. If necessary, remove the injector clamp bolt and clamp.
Illustration 1. Remove Clamp Bolt And Clamp.2. Remove jumper tube by removing two socket head cap screws on one end and loosening the tube nut on the other end. Refer to Illustrations 2 and 3.
Illustration 2. Remove Two Cap Screws.
Illustration 3. Loosen Tube Nut.
Make sure the small seat, shown in Illustration 4, is removed. Do not allow the seat to fall into any engine cavity, which could result in damage if unintentionally left inside the engine.Also, make sure the jumper tube is kept clean at all times. Dirt or other debris can get into the engine with this tube removed and cause possible damage.
Illustration 4. Do Not Lose Or Misplace Tube Seat.3. Remove four bolts and rocker arm assembly.
Illustration 5. Remove Rocker Arm Assembly.4. Remove inlet manifold bolt, as shown in Illustration 6.
Illustration 6. Remove Manifold Bolt.5. Remove the unit injector.6. Install a new injector brass sleeve or inspect and ream the existing sleeves as outlined in Tool Operating Manual NEHS0675. It is not necessary to ream new sleeves when using this procedure.7. Install the unit injector.
Do not install the injectors "off-engine" because the injector tip will protrude from the head and be subject to damage. If the injectors are installed off-engine, make sure the bottom surface of the head is raised off the surface of the work bench.
8. Install the injector forcing cover (8). Make sure the extending portion (small dowel) is in the oil supply hole of the injector. Also make sure wear button (10) is in place.
Illustration 7. Install Injector Forcing Cover (8) With Wear Button (10).9. Place a small amount of 4C-5591 Thread Lubricant on top of the injector forcing cover's wear button (10) and on the threads of forcing bolt (4).
Complete lubrication of the wear button and forcing bolt must be maintained for each injector seating procedure. Failure to relubricate each part before seating the next injector may cause premature wear or tool damage. Also, make sure the forcing bolt turns freely and does not have any damaged threads.
Illustration 8. Put A Small Amount Of Thread Lubricant On Wear Button.10. Install the forcing bridge with three 7X-0457 Bolts (5) and three 9M-1974 Hard Washers (6). Put the two long legs of the forcing bridge in the two rocker arm shaft support holes closest to the injector. The short leg of the forcing bridge sits on the intake manifold bolt boss.
Illustration 9. Install Forcing Bridge.11. Tighten forcing bridge mounting bolts (5) to 28 7 N m, 2.9 0.7 meter kg, (21 5 lb. ft.).
Damage to the head could occur if bridge mounting bolts (5) are not tightened to the specified torque.
Illustration 10. Tighten Forcing Bridge Bolts.12. Tighten the forcing bolt finger tight.13. Use a 9U-5019 Torque Wrench and tighten the forcing bolts to 34 1.4 N m, 3.5
Illustration 1. Remove Clamp Bolt And Clamp.2. Remove jumper tube by removing two socket head cap screws on one end and loosening the tube nut on the other end. Refer to Illustrations 2 and 3.
Illustration 2. Remove Two Cap Screws.
Illustration 3. Loosen Tube Nut.
Make sure the small seat, shown in Illustration 4, is removed. Do not allow the seat to fall into any engine cavity, which could result in damage if unintentionally left inside the engine.Also, make sure the jumper tube is kept clean at all times. Dirt or other debris can get into the engine with this tube removed and cause possible damage.
Illustration 4. Do Not Lose Or Misplace Tube Seat.3. Remove four bolts and rocker arm assembly.
Illustration 5. Remove Rocker Arm Assembly.4. Remove inlet manifold bolt, as shown in Illustration 6.
Illustration 6. Remove Manifold Bolt.5. Remove the unit injector.6. Install a new injector brass sleeve or inspect and ream the existing sleeves as outlined in Tool Operating Manual NEHS0675. It is not necessary to ream new sleeves when using this procedure.7. Install the unit injector.
Do not install the injectors "off-engine" because the injector tip will protrude from the head and be subject to damage. If the injectors are installed off-engine, make sure the bottom surface of the head is raised off the surface of the work bench.
8. Install the injector forcing cover (8). Make sure the extending portion (small dowel) is in the oil supply hole of the injector. Also make sure wear button (10) is in place.
Illustration 7. Install Injector Forcing Cover (8) With Wear Button (10).9. Place a small amount of 4C-5591 Thread Lubricant on top of the injector forcing cover's wear button (10) and on the threads of forcing bolt (4).
Complete lubrication of the wear button and forcing bolt must be maintained for each injector seating procedure. Failure to relubricate each part before seating the next injector may cause premature wear or tool damage. Also, make sure the forcing bolt turns freely and does not have any damaged threads.
Illustration 8. Put A Small Amount Of Thread Lubricant On Wear Button.10. Install the forcing bridge with three 7X-0457 Bolts (5) and three 9M-1974 Hard Washers (6). Put the two long legs of the forcing bridge in the two rocker arm shaft support holes closest to the injector. The short leg of the forcing bridge sits on the intake manifold bolt boss.
Illustration 9. Install Forcing Bridge.11. Tighten forcing bridge mounting bolts (5) to 28 7 N m, 2.9 0.7 meter kg, (21 5 lb. ft.).
Damage to the head could occur if bridge mounting bolts (5) are not tightened to the specified torque.
Illustration 10. Tighten Forcing Bridge Bolts.12. Tighten the forcing bolt finger tight.13. Use a 9U-5019 Torque Wrench and tighten the forcing bolts to 34 1.4 N m, 3.5
Have questions with 101602-5040?
Group cross 101602-5040 ZEXEL
Hino
101602-5040
9 400 614 866
220205910A
INJECTION-PUMP ASSEMBLY
H07D
H07D