101603-2440 ZEXEL 9 400 610 648 BOSCH INJECTION-PUMP ASSEMBLY 9400610648 1016032440 220205160a


101603-2440 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 648 9400610648
ZEXEL 101603-2440 1016032440
HINO 220205160A 220205160a

Service parts 101603-2440 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5400
3. GOVERNOR 105921-9250
4. SUPPLY PUMP 105210-5240
5. AUTOM. ADVANCE MECHANIS 105672-0480
6. COUPLING PLATE 105662-1160
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6610
11. Nozzle and Holder 23600-2360A
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105030-4410
14. NOZZLE 105015-8980
15. NOZZLE SET

Include in #1:

101603-2440 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 610 648 9400610648
ZEXEL 101603-2440 1016032440
HINO 220205160A 220205160a


Zexel num
Bosch num
Firm num
Name
101603-2440 
9 400 610 648 
220205160A  HINO
INJECTION-PUMP ASSEMBLY
H07D * 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   131424-8320
Overflow valve opening pressure kPa   108 88 128
Overflow valve opening pressure kgf/cm2   1.1 0.9 1.3
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   3.8 3.77 3.83
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   -
Rack position   11.6
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   79.5 77.9 81.1
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   9+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   16 15 17
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.6)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   79.5 78.5 80.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   90 86 94
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.65
Pump speed r/min   580 580 580
Average injection quantity mm3/st.   60 56 64
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   140 140 150
Fixing the lever   *
Rack limit   *
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   1350
Remarks
Measure the actual advance angle.
 
Timer adjustment_04
Pump speed r/min   -
Advance angle deg.   2.5 2.2 2.8
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101603-2440
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=M38
----------

Speed control lever angle

Test data 101603-2440
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=35.5deg+-3deg b=40.5deg+-5deg

Stop lever angle

Test data 101603-2440
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

Timing setting

Test data 101603-2440
(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 101603-2440?





Group cross 101603-2440 ZEXEL

 
 
INJECTION-PUMP ASSEMBLY

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9 400 610 648 
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J-2
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J-2
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Hino 

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J-2
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Hino 

9 400 611 595 
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Hino 

 
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9 400 611 436 
 
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Hino 

9 400 611 596 
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