101602-5040 ZEXEL 9 400 614 866 BOSCH INJECTION-PUMP ASSEMBLY 9400614866 1016025040 220205910a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 866 9400614866

ZEXEL 101602-5040 1016025040

HINO 220205910A 220205910a

Service parts 101602-5040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5480

3. GOVERNOR 105400-8480

4. SUPPLY PUMP 105210-5640

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5140

11. Nozzle and Holder 236003390A

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

13. NOZZLE-HOLDER 105030-4950

14. NOZZLE 105025-1060

15. NOZZLE SET

Include in #1:

101401-0433 as _

101602-5040 as INJECTION-PUMP ASSEMBLY

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

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 4.8 4.77 4.83

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 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.

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.

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
----------

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

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