101603-2252 ZEXEL 9 400 610 640 BOSCH INJECTION-PUMP ASSEMBLY 9400610640 1016032252 220009060b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 640 9400610640

ZEXEL 101603-2252 1016032252

HINO 220009060B 220009060b

Service parts 101603-2252 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5440

3. GOVERNOR 105921-8491

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105672-0540

6. COUPLING PLATE 105662-1580

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4450

11. Nozzle and Holder 23600-2830A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-4730

14. NOZZLE 105025-0780

15. NOZZLE SET

Include in #1:

101603-2252 as INJECTION-PUMP ASSEMBLY

101603-7506 as _

Cross reference number

BOSCH 9 400 610 640 9400610640

ZEXEL 101603-2252 1016032252

HINO 220009060B 220009060b

Zexel num

Bosch num

Firm num

Name

101603-2252

9 400 610 640

220009060B HINO

INJECTION-PUMP ASSEMBLY
H07D K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2090

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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)
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 4 3.97 4.03

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 11.3

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93 91 95

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 Z

Rack position 9+-0.5

Pump speed r/min 265 265 265

Each cylinder's injection qty mm3/st. 15 14 16

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93 92 94

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.7

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 95.5 91.5 99.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position (R1-0.7)

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 77.5 73.5 81.5

Fixing the lever *

Injection quantity adjustment_06

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 1100+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1450-50

Advance angle deg. 3.5 3.2 3.8

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=L84
----------

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+0.45)+-0.1mm Rb=(R1+0.45)+-0.1mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)