101603-2280 ZEXEL 9 400 610 642 BOSCH INJECTION-PUMP ASSEMBLY 9400610642 1016032280 220204620a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 642 9400610642

ZEXEL 101603-2280 1016032280

HINO 220204620A 220204620a

Service parts 101603-2280 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9780

3. GOVERNOR 105401-0641

4. SUPPLY PUMP 105220-5540

5. AUTOM. ADVANCE MECHANIS 105676-0990

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5230

11. Nozzle and Holder 23600-2700A

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

13. NOZZLE-HOLDER 105041-5140

14. NOZZLE 105015-9420

15. NOZZLE SET

Include in #1:

101603-2280 as INJECTION-PUMP ASSEMBLY

101603-7590 as _

Cross reference number

BOSCH 9 400 610 642 9400610642

ZEXEL 101603-2280 1016032280

HINO 220204620A 220204620a

Zexel num

Bosch num

Firm num

Name

101603-2280
101603-2281

9 400 610 642

220204620A HINO

INJECTION-PUMP ASSEMBLY
W06D-T * 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 4.4 4.35 4.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 11

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 84.5 83 86

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.6+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 0.7 0.4 1

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1.5 1.5 1.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Deliver with boost compensator not operating. (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=9 N1=1100r/min N2=700r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(6deg)+-5deg b=(24deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

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)