101603-2100 ZEXEL 9 400 619 759 BOSCH INJECTION-PUMP ASSEMBLY 9400619759 1016032100 220008350a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 759 9400619759

ZEXEL 101603-2100 1016032100

HINO 220008350A 220008350a

Service parts 101603-2100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6170

3. GOVERNOR 105932-0240

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105681-5270

6. COUPLING PLATE 105662-1460

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7705

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-3601

14. NOZZLE

15. NOZZLE SET 105019-0314

Include in #1:

101603-2100 as INJECTION-PUMP ASSEMBLY

101603-8500 as _

Cross reference number

BOSCH 9 400 619 759 9400619759

ZEXEL 101603-2100 1016032100

HINO 220008350A 220008350a

Zexel num

Bosch num

Firm num

Name

101603-2100
101603-2101

9 400 619 759

220008350A HINO

INJECTION-PUMP ASSEMBLY
J-2 * 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 -

Rack position 12.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87 85 89

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 9.5+-0.5

Pump speed r/min 630 630 630

Each cylinder's injection qty mm3/st. 13 12 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87 86 88

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.65

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 101 97 105

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.95 )

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 66 62 70

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.15

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 90.5 86.5 94.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 120 130

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 1/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.25 0.95 1.55

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min (1190++)

Advance angle deg. 1.25 0.95 1.55

Load 2/5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1255-50

Advance angle deg. 1.25 0.95 1.55

Load 5/5

Timer adjustment_06

Pump speed r/min 1420-50

Advance angle deg. 5.5 5.2 5.8

Load 5/5

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=J43
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=6deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg

Timing setting

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

----------
a=(20deg)

Have questions with 101603-2100?

Group cross 101603-2100 ZEXEL

Hino

101603-2100

101603-2101

9 400 619 759

220008350A

INJECTION-PUMP ASSEMBLY
J-2

101603-2101

101603-2102

220008350B

INJECTION-PUMP ASSEMBLY
J-2

101603-2102

101603-2103

220008350D

INJECTION-PUMP ASSEMBLY
J-2

101603-2103

101603-2104

220008351A

INJECTION-PUMP ASSEMBLY

101603-2103

101603-2104

220008351B

INJECTION-PUMP ASSEMBLY

101603-2104

101603-2105

F 01G 09U 03G

INJECTION-PUMP ASSEMBLY

Hino

101603-2105

F 019 Z10 110

220008351C

INJECTION-PUMP ASSEMBLY
J-2