101602-5120 ZEXEL 9 400 613 467 BOSCH INJECTION-PUMP ASSEMBLY 9400613467 1016025120 220206460a


101602-5120 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 467 9400613467
ZEXEL 101602-5120 1016025120
HINO 220206460A 220206460a

Service parts 101602-5120 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6840
3. GOVERNOR 105411-2770
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 236003410A
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:

101602-5120 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 613 467 9400613467
ZEXEL 101602-5120 1016025120
HINO 220206460A 220206460a


Zexel num
Bosch num
Firm num
Name
101602-5120 
101602-5121 
9 400 613 467 
220206460A  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   10.3
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   141 139 143
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Boost pressure kPa   36 36
Boost pressure mmHg   270 270
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.3+-0.5
Pump speed r/min   390 390 390
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   10.5++
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
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_02
Pump speed r/min   700 700 700
Rack position   10.3
Boost pressure kPa   22.7 22.7 22.7
Boost pressure mmHg   170 170 170

Test data Ex:

Governor adjustment

Test data 101602-5120
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting (5)Damper spring setting: DL (6)Boost compensator stroke: BCL
----------
K=10 DL=4.6+-0.1mm BCL=1.3+-0.1mm
----------

Speed control lever angle

Test data 101602-5120
F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=100mm
----------
a=(7deg)+-5deg b=(23deg)+-5deg

Stop lever angle

Test data 101602-5120
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)

Timing setting

Test data 101602-5120
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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Group cross 101602-5120 ZEXEL

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