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101603-2800 ZEXEL 9 400 615 066 BOSCH INJECTION-PUMP ASSEMBLY 9400615066 1016032800 220206430a


101603-2800 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 066 9400615066
ZEXEL 101603-2800 1016032800
HINO 220206430A 220206430a

Service parts 101603-2800 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6820
3. GOVERNOR 105411-2700
4. SUPPLY PUMP 105210-6060
5. AUTOM. ADVANCE MECHANIS 105680-5120
6. COUPLING PLATE 105662-1520
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-8671
11. Nozzle and Holder 236003581A
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-3700
14. NOZZLE
15. NOZZLE SET 105019-2861

Include in #1:

101442-0090 as _
101603-2800 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 066 9400615066
ZEXEL 101603-2800 1016032800
HINO 220206430A 220206430a


Zexel num
Bosch num
Firm num
Name
101603-2800 
9 400 615 066 
220206430A  HINO
INJECTION-PUMP ASSEMBLY
J08C-T 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   11.4
Pump speed r/min   1050 1050 1050
Average injection quantity mm3/st.   133.5 131.5 135.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Boost pressure kPa   34 34
Boost pressure mmHg   255 255
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.5+-0.5
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   8 7 9
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   E
Rack position   11.6++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   100 100 110
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   10.4
Boost pressure kPa   18 15.3 20.7
Boost pressure mmHg   135 115 155
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   10.7
Boost pressure kPa   20.7 20.7 20.7
Boost pressure mmHg   155 155 155
Timer adjustment
Pump speed r/min   600--
Advance angle deg.   0 0 0
Load   0/4
Remarks
Start  
Timer adjustment_02
Pump speed r/min   550
Advance angle deg.   0 -0.3 0
Load   0/4
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   -1.5 -1.8 -1.2
Load   0/4
Remarks
Measure the actual speed, stop  
Timer adjustment_04
Pump speed r/min   -
Advance angle deg.   0 0 0
Load   4/4
Remarks
Measure speed (beginning of operation).  
Timer adjustment_05
Pump speed r/min   800-50
Advance angle deg.   -1.5 -1.8 -1.2
Load   4/4
Remarks
Finish  

Test data Ex:

Governor adjustment

Test data 101603-2800
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Rack difference between N = N1 and N = N2 (6)Idle sub spring setting: L1.
----------
K=15 BCL=0.3+-0.1mm N1=1050r/min N2=500r/min L1=7.8+-0.2mm
----------

Speed control lever angle

Test data 101603-2800
F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=100mm
----------
a=(7deg)+-5deg b=(23deg)+-5deg

Stop lever angle

Test data 101603-2800
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Stopper bolt setting (3)Speed = bb, rack position = cc (sealed at delivery) (4)Normal stop (5)Stopper bolt setting
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=50deg+-5deg b=13deg+-5deg

Timing setting

Test data 101603-2800
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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Group cross 101603-2800 ZEXEL

Hino 

101603-2800  
9 400 615 066 
220206430A 
INJECTION-PUMP ASSEMBLY
J08C-T
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