101603-2092 ZEXEL 9 400 615 039 BOSCH INJECTION-PUMP ASSEMBLY 9400615039 1016032092 220204400a


101603-2092 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 039 9400615039
ZEXEL 101603-2092 1016032092
HINO 220204400A 220204400a

Service parts 101603-2092 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5311
3. GOVERNOR 105401-0650
4. SUPPLY PUMP 105210-5570
5. AUTOM. ADVANCE MECHANIS 105614-3660
6. COUPLING PLATE 105662-1280
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4100
11. Nozzle and Holder 236002710A
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105030-4440
14. NOZZLE 105015-9220
15. NOZZLE SET

Include in #1:

101603-2092 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 039 9400615039
ZEXEL 101603-2092 1016032092
HINO 220204400A 220204400a


Zexel num
Bosch num
Firm num
Name
101603-2092 
9 400 615 039 
220204400A  HINO
INJECTION-PUMP ASSEMBLY
H07C-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   4.8 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   11.9
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   124.5 123 126
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.4+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   130 130 140
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   R1-1.4
Boost pressure kPa   4.7 2 7.4
Boost pressure mmHg   35 15 55
Boost compensator adjustment_02
Pump speed r/min   800 800 800
Rack position   R1(11.9)
Boost pressure kPa   20 13.3 26.7
Boost pressure mmHg   150 100 200
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-2092
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)Main spring setting (6)Boost compensator stroke: BCL
----------
K=14 BCL=1.4+-0.1mm
----------

Speed control lever angle

Test data 101603-2092
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=25deg+-5deg

Stop lever angle

Test data 101603-2092
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

Test data 101603-2092
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)




Have questions with 101603-2092?





Group cross 101603-2092 ZEXEL

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Hino 

101603-2092  
9 400 615 039 
220204400A 
INJECTION-PUMP ASSEMBLY
H07C-T
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