101603-2021 ZEXEL 9 400 615 034 BOSCH INJECTION-PUMP ASSEMBLY 9400615034 1016032021 220008070b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 034 9400615034

ZEXEL 101603-2021 1016032021

HINO 220008070B 220008070b

Service parts 101603-2021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9550

3. GOVERNOR 105921-6320

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0861

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101603-2021 as INJECTION-PUMP ASSEMBLY

101603-8351 as _

Cross reference number

BOSCH 9 400 615 034 9400615034

ZEXEL 101603-2021 1016032021

HINO 220008070B 220008070b

Zexel num

Bosch num

Firm num

Name

101603-2021

9 400 615 034

220008070B HINO

INJECTION-PUMP ASSEMBLY
W06E * 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.45 3.42 3.48

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 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 56.8 60.8

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 9.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 17.1 16.1 18.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 57.8 59.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 59.3 55.3 63.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.7 49.7 57.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 123 123 133

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

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=H37
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=(27deg)+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)(Apply red paint after setting.) (3)Stopper bolt setting
----------
aa=17+-0.1mm
----------
a=40deg+-5deg b=40deg+-5deg c=(35deg)

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 aa using the load lever. (3)At N = N1, push in screw (A) until Ra. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is Rb. (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
aa=R1(11.2)+0.4mm N1=1500r/min Ra=R1(11.2)+0.4mm Rb=R1(11.2)+0.4mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)