101603-2473 ZEXEL 9 400 611 595 BOSCH INJECTION-PUMP ASSEMBLY 9400611595 1016032473 220205120b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 595 9400611595

ZEXEL 101603-2473 1016032473

HINO 220205120B 220205120b

Service parts 101603-2473 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5431

3. GOVERNOR 105401-1001

4. SUPPLY PUMP 105210-5570

5. AUTOM. ADVANCE MECHANIS 105672-0470

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4270

11. Nozzle and Holder 23600-2820A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105025-0570

15. NOZZLE SET

Include in #1:

101603-2473 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6470 as _

Cross reference number

BOSCH 9 400 611 595 9400611595

ZEXEL 101603-2473 1016032473

HINO 220205120B 220205120b

Zexel num

Bosch num

Firm num

Name

101603-2473

9 400 611 595

220205120B HINO

INJECTION-PUMP ASSEMBLY
H07C-T K 14BF INJECTION PUMP ASSY PE6AD PE

101603-2473

9 400 611 595

S220205120 HINO

INJECTION-PUMP ASSEMBLY
H07C-T A 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 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 4.8 4.77 4.83

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 A

Rack position 10

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 114.5 113 116

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.85

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10)

Boost pressure kPa 18 14 22

Boost pressure mmHg 135 105 165

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 1050

Advance angle deg. 1.5 1.2 1.8

Remarks
Finish

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)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Main spring setting
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K=13 BCL=0.85+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(6deg)+-5deg b=(20deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
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aa=0r/min bb=1-0.5mm
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a=21deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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