101602-2471 ZEXEL 9 400 612 197 BOSCH INJECTION-PUMP ASSEMBLY 9400612197 1016022471 220203521a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 197 9400612197

ZEXEL 101602-2471 1016022471

HINO 220203521A 220203521a

Service parts 101602-2471 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9440

3. GOVERNOR 105401-0371

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-8820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4380

11. Nozzle and Holder 23600-1780

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5090

14. NOZZLE 105015-7080

15. NOZZLE SET

Include in #1:

101602-2471 as INJECTION-PUMP ASSEMBLY

103670-0041 as _

Cross reference number

BOSCH 9 400 612 197 9400612197

ZEXEL 101602-2471 1016022471

HINO 220203521A 220203521a

Zexel num

Bosch num

Firm num

Name

101602-2471

9 400 612 197

220203521A HINO

INJECTION-PUMP ASSEMBLY
W06D-TI K 14BE INJECTION PUMP ASSY PE6A 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 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.2 3.15 3.25

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

Adjusting point A

Rack position 10.3

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 102.4 100.4 104.4

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 9.1

Boost pressure kPa 10.7 8 13.4

Boost pressure mmHg 80 60 100

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position (10.3)

Boost pressure kPa 33.3 26.6 40

Boost pressure mmHg 250 200 300

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke (at N = N1)
----------
K=10 N1=600r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(13deg)+-5deg b=(26deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

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)