101601-5184 ZEXEL 9 400 614 603 BOSCH INJECTION-PUMP ASSEMBLY 9400614603 1016015184 220005201a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 603 9400614603

ZEXEL 101601-5184 1016015184

HINO 220005201A 220005201a

Include in #1:

106682-4723 as _

Cross reference number

BOSCH 9 400 614 603 9400614603

ZEXEL 101601-5184 1016015184

HINO 220005201A 220005201a

Zexel num

Bosch num

Firm num

Name

101601-5184

9 400 614 603

220005201A HINO

INJECTION-PUMP ASSEMBLY
H07C * 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

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 3.07 3.13

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 9.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 70 69 71

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 -

Rack position 7+-0.1

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 70 69 71

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 4 3.5 4.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
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T1=B94
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=33deg+-5deg b=(45deg)+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (After setting, apply red paint.)
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----------
a=0deg+-5deg b=(24deg)+-5deg

0000001501 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
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N1=900r/min Ra=R1(9.4)mm VR=1.75+-0.18V
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0000001601 LEVER

(N) Engine normal (pump normal) (S) Engine stop (A) stopper screw (B) Stop direction (perpendicular) Stop lever adjusting procedure (1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above. (2)With the speed ever at Full and the pump speed (specified speed) at non-injection set the stopper screw (A) so that the non-injection position R = Ra. (3)After setting, confirm non-injection at speed lever idle and pump speed Na. (4)After adjustment, apply red paint.
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Na=275r/min Ra=(4.8)mm
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ra=37mm a=0deg+-5deg b=(24deg)+-5deg