101602-2942 ZEXEL 9 400 611 209 BOSCH INJECTION-PUMP ASSEMBLY 9400611209 1016022942 220205233a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 209 9400611209

ZEXEL 101602-2942 1016022942

HINO 220205233A 220205233a

Service parts 101602-2942 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6590

3. GOVERNOR 105411-1913

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1520

7. COUPLING PLATE 156639-8920

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4780

11. Nozzle and Holder 23600-3170A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-2010

14. NOZZLE 105025-1800

15. NOZZLE SET

Include in #1:

101602-2942 as INJECTION-PUMP ASSEMBLY

101603-8661 as _

Cross reference number

BOSCH 9 400 611 209 9400611209

ZEXEL 101602-2942 1016022942

HINO 220205233A 220205233a

Zexel num

Bosch num

Firm num

Name

101602-2942
101602-2943

9 400 611 209

220205233A HINO

INJECTION-PUMP ASSEMBLY
J08C-TN * 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 131425-0620

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)
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 3.8 3.77 3.83

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 A

Rack position 8.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 87 85 89

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Injection quantity adjustment_02

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 8.5 7.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 105 115

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-1.2

Boost pressure kPa 4.7 3.4 6

Boost pressure mmHg 35 25 45

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(8.8)

Boost pressure kPa 29.3 22.6 36

Boost pressure mmHg 220 170 270

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)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=8 BCL=1.2+-0.1mm
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)