101603-2290 ZEXEL 9 400 610 643 BOSCH INJECTION-PUMP ASSEMBLY 9400610643 1016032290 220204660a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 643 9400610643

ZEXEL 101603-2290 1016032290

HINO 220204660A 220204660a

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Buy INJECTION-PUMP ASSEMBLY 101603-2290 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2290 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9940

3. GOVERNOR 105402-2590

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-1010

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder 23600-2142A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101603-2290 as INJECTION-PUMP ASSEMBLY

101603-7593 as _

Cross reference number

BOSCH 9 400 610 643 9400610643

ZEXEL 101603-2290 1016032290

HINO 220204660A 220204660a

Zexel num

Bosch num

Firm num

Name

101603-2290
101603-2291

9 400 610 643

220204660A HINO

INJECTION-PUMP ASSEMBLY
W06E * K 14BE 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 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 3.45 3.42 3.48

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 9

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 37.8 35.8 39.8

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 13.5 12 15

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 90

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 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)Main spring setting (5)Set idle sub-spring (6)Set the torque spring.
----------
K=14
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=17deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=7.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

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:

1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the flywheel housing.2. Force the crankshaft toward the rear before an indication is taken on the indicator at each point. 3. With dial indicator set at "0" (zero) at location (A), turn the crankshaft and read the indicator at locations (B), (C) and (D).4. The difference between lower and higher measurements taken at all four points must not be more than 0.20 mm (.008 in.)Bore Runout
Write the dial indicator measurements with their positive (+) and negative (-) notation (signs). This notation is necessary when the calculations are made in the chart correctly. 1. Fasten a dial indicator to the crankshaft flange so the 7H1940 Universal Attachment of the indicator is in contact with the inner flywheel housing bore at location (C). Adjust the dial indicator to "0" (zero). Push the crankshaft up against the top crankshaft bearing. Write the measurement for bearing clearance on line 1 in column (C) of the chart.2. Divide the measurement from Step 1 by 2. Write this number on line in columns (B) and (D). 3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the chart.5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the chart.6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurement in the chart.7. Add lines I and II by columns. 8. Subtract the smaller number from the larger number in line II in columns (B) and (D). The result is the horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity. 9. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.10. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of intersection is in the range marked "Not Acceptable", the flywheel housing must be changed.