101603-2241 ZEXEL 9 400 610 639 BOSCH INJECTION-PUMP ASSEMBLY 9400610639 1016032241 220204601a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 639 9400610639

ZEXEL 101603-2241 1016032241

HINO 220204601A 220204601a

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Buy INJECTION-PUMP ASSEMBLY 101603-2241 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2241 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5410

3. GOVERNOR 105401-0772

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105672-0500

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4100

11. Nozzle and Holder 23600-2710A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101603-2241 as INJECTION-PUMP ASSEMBLY

101603-7505 as _

Cross reference number

BOSCH 9 400 610 639 9400610639

ZEXEL 101603-2241 1016032241

HINO 220204601A 220204601a

Zexel num

Bosch num

Firm num

Name

101603-2241

9 400 610 639

220204601A HINO

INJECTION-PUMP ASSEMBLY
H07C-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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 4.8 4.77 4.83

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 A

Rack position 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 94 92.5 95.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 24.7 24.7

Boost pressure mmHg 185 185

Injection quantity adjustment_02

Adjusting point -

Rack position 6+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

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 D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 130 140

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 R1-0.8

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.8)

Boost pressure kPa 11.3 11.3 11.3

Boost pressure mmHg 85 85 85

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 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)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=12 BCL=0.8+-0.1mm
----------

Speed control lever angle

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

----------
a=17deg+-5deg b=36deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

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

----------
a=(50deg)

Information:

Flangeless Liners
(1) Outside diameter of cylinder liner ... 103.264 to 103.289 mm (4.0655 to 4.0665 in)(2) Inside diameter of cylinder liners ... 98.48 to 98.50 mm (3.877 to 3.878 in) Maximum diameter wear (when boring or new liners are needed) ... 0.20 mm (.008 in)Interference fit of liner in cylinder block ... 0.08 to 0.13 mm (.003 to .005 in)Length of cylinder liner ... 228.73 to 228.98 mm (9.005 to 9.015 in)Maximum cylinder liner can be bored (made larger than original size) ... 0.76 mm (.030 in) The flangeless cylinder liners are the only ones that can be bored. All other liners must be replaced when worn beyond specifications. The five ring pistons are the only ones offered in oversize.(3) Liner projection (height of liner above face of cylinder block) ... 0.71 to 0.94 mm (.028 to .037 in)(4) Diameter of bore in cylinder block for liner ... 103.162 to 103.188 mm (4.0615 to 4.0625 in)Flanged Liners
New cylinder blocks have been introduced on 4.236 and T4.236 engin s. They have a larger cylinder liner parent bore diameter and the outside diameter of the cylinder liner is also larger. The liners will no longer have a flame ring. Effective with this change, only flanged liners will be available. The change became effective at engine serial number LD or LJ----- U106654N and up. The engine serial number is located above the fuel injection pump on the block.(1) Outside diameter of cylinder linerEarlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service Liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed) ... 0.20 mm (.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( .001 in)Length of cylinder liner ... 227.10 to 227.43 mm (8.941 to 8.954 in)(3) Liner (flange) projection [do not measure projection from flange ring (if equipped)] ... 0.10 mm (.004 in) above to ... 0.10 mm (.004 in) below face of cylinder block. Flange thickness of cylinder liner ... 3.81 to 3.86 mm (.150 to .152 in)(4) Diameter of parent bore in cylinder block for liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (.150 to .154 in)All Engine Blocks
(5) Diameter of bore in cylinder block