101602-5060 ZEXEL 9 400 612 203 BOSCH INJECTION-PUMP ASSEMBLY 9400612203 1016025060 220206080a


101602-5060 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 203 9400612203
ZEXEL 101602-5060 1016025060
HINO 220206080A 220206080a

Service parts 101602-5060 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6710
3. GOVERNOR 105411-2210
4. SUPPLY PUMP 105210-6060
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156639-8920
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-8601
11. Nozzle and Holder 23600-3410A
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-3700
14. NOZZLE
15. NOZZLE SET 105019-2611

Include in #1:

101602-5060 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 612 203 9400612203
ZEXEL 101602-5060 1016025060
HINO 220206080A 220206080a


Zexel num
Bosch num
Firm num
Name
101602-5060 
101602-5061 
9 400 612 203 
220206080A  HINO
INJECTION-PUMP ASSEMBLY
J08C-T * 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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   9.1
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   107.5 105.5 109.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
Boost pressure kPa   133 133
Boost pressure mmHg   1000 1000
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.9
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   103 100 106
Fixing the rack   *
Boost pressure kPa   133 133
Boost pressure mmHg   1000 1000
Injection quantity adjustment_03
Adjusting point   D
Rack position   6.5+-0.5
Pump speed r/min   360 360 360
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
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   R1-1.8
Boost pressure kPa   66.7 64 69.4
Boost pressure mmHg   500 480 520
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R1(9.3)
Boost pressure kPa   120 120 120
Boost pressure mmHg   900 900 900

Test data Ex:

Governor adjustment

Test data 101602-5060
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Boost compensator stroke: BCL (5)Set idle sub-spring
----------
K=11 L1=10.5+-0.1mm BCL=1.8+-0.1mm
----------

Speed control lever angle

Test data 101602-5060
F:Full speed I:Idle (1)Set the pump speed at aa (2)When pump speed set at bb (3)Stopper bolt setting (4)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=22deg+-5deg b=1deg+-5deg c=6deg+-5deg

Stop lever angle

Test data 101602-5060
N:Pump normal S:Stop the pump. (1)Normal stop (2)Rack position aa or less, pump speed bb
----------
aa=6mm bb=0r/min
----------
a=19deg+-5deg b=53deg+-5deg

0000001101

Test data 101602-5060
N:Normal B:When boosted (1)Rack position = aa (2)Stopper bolt setting (3)Use the hole at R = bb (4)Drive side (5)At boost pressure = cc
----------
aa=10.5+-0.1mm bb=30mm cc=0kPa(0mmHg)
----------
a=(11deg) b=(5deg)

Timing setting

Test data 101602-5060
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)




Have questions with 101602-5060?





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