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

Information Cross number Calibration Data Calibration Data Ex

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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:

104749-1880 as _

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

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

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

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

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)