101602-5101 ZEXEL 9 400 613 497 BOSCH INJECTION-PUMP ASSEMBLY 9400613497 1016025101 220206410b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 497 9400613497

ZEXEL 101602-5101 1016025101

HINO 220206410B 220206410b

Service parts 101602-5101 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6840

3. GOVERNOR 105411-2750

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 105101-8601

11. Nozzle and Holder 236003411A

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:

101602-5101 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-1102 as _

Cross reference number

BOSCH 9 400 613 497 9400613497

ZEXEL 101602-5101 1016025101

HINO 220206410B 220206410b

Zexel num

Bosch num

Firm num

Name

101602-5101
101602-5102

9 400 613 497

220206410B HINO

INJECTION-PUMP ASSEMBLY
J08C-TI * K 14BN INJECTION PUMP ASSY 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 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 9.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 102 100 104

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_02

Adjusting point -

Rack position 6.4+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position 9.7++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 150 160

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 9.3

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 9.5

Boost pressure kPa 10 10 10

Boost pressure mmHg 75 75 75

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Damper spring setting: DL (7)Boost compensator stroke: BCL
----------
K=11 DL=4.5+-0.1mm BCL=0.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=100mm
----------
a=(14deg)+-5deg b=(27deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb, pump speed cc (seal at delivery) (3)Normal
----------
aa=25mm bb=1-0.5mm cc=0r/min
----------
a=21deg+-5deg b=(55deg)