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

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 041 9400615041

ZEXEL 101603-2151 1016032151

HINO 220008590B 220008590b

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Buy INJECTION-PUMP ASSEMBLY 101603-2151 zexel genuine, new aftermarket engine parts with delivery

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

101603-8720 as _

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

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

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

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

Stop lever angle

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

(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

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

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

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

Information:

Illustration 16 g00628694
(9) Fuel injector clamp. (10) Bolt. (11) O-ring seal.
Place the clamp (9) in the proper position. Temporarily place the jumper tube in position in order to ensure alignment of the bolt holes. Adjust the orientation of the injector until the alignment is satisfactory. Torque the bolt (10) to the following torque. Remove the jumper tube.Torque for bolt ... 47 9 N m (35 7 lb ft)
Illustration 17 g00628691
(12) O-ring seals in the injector jumper tube. (13) O-ring seals in the base of the rocker arm.
Replace the used O-ring seal (11), and the O-ring seals (12) and (13) in the jumper tube and in the rocker arm.
Illustration 18 g00628693
(14) Jumper tube. (15) Bolts. (16) Adapter. (17) Socket head screws.
Place the jumper tube (14) and the adapter (16) into position.
If the adapter was previously installed on the injector, loosen the socket head screws. Failure to loosen the socket head screws before continuing with Step 8 can result in injector failure.
Install the socket head screws (17) and the four bolts (15) finger tight.Note: The mating surfaces should be brought into complete contact and into alignment before the final torque procedure is started.
Failure to follow any of the procedures in this instruction may result in injector damage or malfunction, and possible major engine damage.
Torque Procedure
Illustration 19 g00338156
(1) Socket head screws.
Illustration 20 g00338157
(2) Two horizontal bolts. (3) Two vertical bolts.
Tighten the socket head screws (1), the two horizontal bolts (2), and the two vertical bolts (3) finger tight.
Tighten the socket head screws (1) to an initial torque of 1 .2 N m (9 2 lb in).
Tighten the horizontal bolts (2) to an initial torque of 5 3 N m (44 27 lb in).
Tighten the vertical bolts (3) to an initial torque of 5 3 N m (44 27 lb in).
Tighten the socket head screws (1) to a final torque of 12 3 N m (9 2 lb ft).
Tighten the horizontal bolts (2) to a final torque of 47 9 N m (35 7 lb ft).
Tighten the vertical bolts (3) to a final torque of 47 9 N m (35 7 lb ft).
Repeat Step 1 through Step 7 for the remainder of the injectors.
Check the fuel system for leaks by cranking the engine with the disabled injection. Then check the hydraulic pressure. Compare the pressure to the desired pressure.Cranking Without Injecting
Cranking the engine with the disabled injection may be performed by one of the following methods:
Disconnect the injector harness of the cylinders which have been reinstalled. Allow the engine to idle. Visually inspect the injector's components for high pressure oil leaks.
Activate the system "Crank Without Inject" if the option is available. On Track-Type Tractors, a "Crank Without Inject" plug can be assembled in the engine harness. On Off-Highway Trucks, the "Ground Level Shutdown" can be activated if the option is available.
When you are using the CAT ET or the ECAP, the injection may be disabled by interactive diagnostics. The engine can be left