101602-2980 ZEXEL 9 400 611 235 BOSCH INJECTION-PUMP ASSEMBLY 9400611235 1016022980 220401530a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 235 9400611235

ZEXEL 101602-2980 1016022980

HINO 220401530A 220401530a

Service parts 101602-2980 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9140

3. GOVERNOR 105921-9840

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-8820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5272

11. Nozzle and Holder 23600-3301A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-2840

15. NOZZLE SET

Include in #1:

101401-7170 as _

101602-2980 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 235 9400611235

ZEXEL 101602-2980 1016022980

HINO 220401530A 220401530a

Zexel num

Bosch num

Firm num

Name

101602-2980
101602-2981

9 400 611 235

220401530A HINO

INJECTION-PUMP ASSEMBLY
W06E * K 14BF INJECTION PUMP ASSY PE6AD 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 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 3.6 3.57 3.63

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 10.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 57.5 55.5 59.5

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 H

Rack position 9.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 15.5 14.5 16.5

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.9)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 57.5 56.5 58.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 68 64 72

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 660 660 660

Average injection quantity mm3/st. 48.9 44.9 52.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 125 135

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Stop lever setting: RA (4)RACK LIMIT
----------
T1=N35 RA=17+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=34deg+-5deg b=38.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at rack position = bb. (After setting, apply red paint.)
----------
aa=40mm bb=17+-0.1mm
----------
a=(35deg) b=40deg+-5deg c=40deg+-5deg

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)