101603-2560 ZEXEL 9 400 615 056 BOSCH INJECTION-PUMP ASSEMBLY 9400615056 1016032560 220205440a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 056 9400615056

ZEXEL 101603-2560 1016032560

HINO 220205440A 220205440a

Include in #1:

101402-0770 as _

Cross reference number

BOSCH 9 400 615 056 9400615056

ZEXEL 101603-2560 1016032560

HINO 220205440A 220205440a

Zexel num

Bosch num

Firm num

Name

101603-2560

9 400 615 056

220205440A HINO

INJECTION-PUMP ASSEMBLY
J08C-TN 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 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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.8 3.77 3.83

Beginning of injection position
Governor 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 9

Pump speed r/min 1275 1275 1275

Average injection quantity mm3/st. 91.5 89.5 93.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_02

Adjusting point B

Rack position 6.1+-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 8 7 9

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 C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110 120

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 R1-0.3

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(9)

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Timer adjustment

Pump speed r/min 825--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 775

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 1.5 1.2 1.8

Timer adjustment_04

Pump speed r/min (1300)

Advance angle deg. 2.5 2.5 2.5

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)Perform governor adjustment at an ambient temperature of at least 15 deg C (rack limit spring is shape memory alloy). (4)SMA RACK LIMIT (5)Set idle sub-spring (6)Boost compensator stroke: BCL (7)Main spring setting
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K=6 BCL=0.3+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=13deg+-5deg b=22deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Stopper bolt setting (3)Speed = bb, rack position = cc (sealed at delivery) (4)At delivery (5)Stopper bolt setting
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aa=25mm bb=0r/min cc=1-0.5mm
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a=50deg+-5deg b=13deg+-5deg