101603-2503 ZEXEL 9 400 613 499 BOSCH INJECTION-PUMP ASSEMBLY 9400613499 1016032503 220205223a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 499 9400613499

ZEXEL 101603-2503 1016032503

HINO 220205223A 220205223a

Service parts 101603-2503 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6590

3. GOVERNOR 105419-2782

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105672-5450

6. COUPLING PLATE 105663-0970

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8470

11. Nozzle and Holder 236003290A

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

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE 105025-1770

15. NOZZLE SET

Include in #1:

101402-0741 as _

101603-2503 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 499 9400613499

ZEXEL 101603-2503 1016032503

HINO 220205223A 220205223a

Zexel num

Bosch num

Firm num

Name

101603-2503

9 400 613 499

220205223A HINO

INJECTION-PUMP ASSEMBLY
J08C-H K 14BF INJECTION PUMP ASSY PE6AD 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 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 9.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92 90 94

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 395 395 395

Average injection quantity mm3/st. 9.5 8.5 10.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 9.3++

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

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1.5 1.2 1.8

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Damper spring setting
----------
K=14
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=13deg+-5deg b=28deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb (2)Normal
----------
aa=5.8mm bb=0r/min
----------
a=19deg+-5deg b=53deg+-5deg