101603-2151 ZEXEL 9 400 615 041 BOSCH INJECTION-PUMP ASSEMBLY 9400615041 1016032151 220008590b


101603-2151 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 041 9400615041
ZEXEL 101603-2151 1016032151
HINO 220008590B 220008590b

Service parts 101603-2151 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9931
3. GOVERNOR 105921-8000
4. SUPPLY PUMP 105220-5140
5. AUTOM. ADVANCE MECHANIS 105676-0671
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-4292
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105041-5041
14. NOZZLE 105025-0490
15. NOZZLE SET

Include in #1:

101603-2151 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 041 9400615041
ZEXEL 101603-2151 1016032151
HINO 220008590B 220008590b


Zexel num
Bosch num
Firm num
Name
101603-2151 
9 400 615 041 
220008590B  HINO
INJECTION-PUMP ASSEMBLY
W06E K 14BE INJECTION PUMP ASSY PE6A 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   131424-5720
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)
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   3.1 3.07 3.13
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   -
Rack position   9.5
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   60.2 58.2 62.2
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   H
Rack position   8+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   6.8 5.3 8.3
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(9.5)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   60.2 59.2 61.2
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   67.3 63.3 71.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.45
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   37.9 33.9 41.9
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1+0.15
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   67.8 63.8 71.8
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   R1(9.5)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   32.9 28.9 36.9
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   13.9+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99 99 109
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_09
Adjusting point   F
Rack position   R2(10)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   72.765 67.765 77.765
Fixing the lever   *
Remarks
Set tamper proofing.
 
Timer adjustment
Pump speed r/min   1000+50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1500
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-2151
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C10
----------

Speed control lever angle

Test data 101603-2151
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=32deg+-3deg b=34deg+-5deg

Stop lever angle

Test data 101603-2151
N:Pump normal S:Stop the pump. (1)Stopper bolt setting (2)(Apply red paint after setting.) (3)Engine normal
----------

----------
a=40deg+-5deg b=40deg+-5deg c=35deg+-2deg

0000001501 ACS

Test data 101603-2151
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1500r/min L1=(1.5)mm L2=7+-0.5mm h1=-
----------
Ra=R1+0.1mm Rb=R1-1.65mm Pa=(94.6)+-2.7kPa((710)+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=(67.3)+-2cm3/1000st Q2=-

0000001601 TAMPER PROOF

Test data 101603-2151
1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to Ra using the load lever. (3)Push in screw (A) to Rb. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is at Rb . (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
Ra=R2(10)mm Rb=R2(10)mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)

Timing setting

Test data 101603-2151
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)




Have questions with 101603-2151?





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