101603-2012 ZEXEL 9 400 610 635 BOSCH INJECTION-PUMP ASSEMBLY 9400610635 1016032012 220008061b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 635 9400610635

ZEXEL 101603-2012 1016032012

HINO 220008061B 220008061b

Service parts 101603-2012 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5400

3. GOVERNOR 105921-4762

4. SUPPLY PUMP 105210-5240

5. AUTOM. ADVANCE MECHANIS 105672-0480

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6610

11. Nozzle and Holder 23600-2360A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4410

14. NOZZLE 105015-8980

15. NOZZLE SET

Include in #1:

101603-2012 as INJECTION-PUMP ASSEMBLY

101603-8392 as _

Cross reference number

BOSCH 9 400 610 635 9400610635

ZEXEL 101603-2012 1016032012

HINO 220008061B 220008061b

Zexel num

Bosch num

Firm num

Name

101603-2012

9 400 610 635

220008061B HINO

INJECTION-PUMP ASSEMBLY
H07D K 14BF INJECTION PUMP ASSY PE6AD 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 131424-8320

Overflow valve opening pressure kPa 108 88 128

Overflow valve opening pressure kgf/cm2 1.1 0.9 1.3

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 3.8 3.77 3.83

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 -

Rack position 11.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 80 78.4 81.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 16 15 17

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 80 79 81

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 90.5 86.5 94.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.35

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 87 83 91

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.65

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 60.5 56.5 64.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 2.5 2.2 2.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L00
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=57mm
----------
a=40deg+-3deg b=44deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to Ra using the load lever. (3)Push in screw (A) to Rb. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is at Rb . (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
Ra=(R1+0.7)+-0.1mm Rb=(R1+0.7)+-0.1mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)