101603-2440 ZEXEL 9 400 610 648 BOSCH INJECTION-PUMP ASSEMBLY 9400610648 1016032440 220205160a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 648 9400610648

ZEXEL 101603-2440 1016032440

HINO 220205160A 220205160a

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Buy INJECTION-PUMP ASSEMBLY 101603-2440 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2440 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5400

3. GOVERNOR 105921-9250

4. SUPPLY PUMP 105210-5240

5. AUTOM. ADVANCE MECHANIS 105672-0480

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6610

11. Nozzle and Holder 23600-2360A

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

13. NOZZLE-HOLDER 105030-4410

14. NOZZLE 105015-8980

15. NOZZLE SET

Include in #1:

101603-2440 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6051 as _

Cross reference number

BOSCH 9 400 610 648 9400610648

ZEXEL 101603-2440 1016032440

HINO 220205160A 220205160a

Zexel num

Bosch num

Firm num

Name

101603-2440

9 400 610 648

220205160A HINO

INJECTION-PUMP ASSEMBLY
H07D * K

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 131424-8320

Overflow valve opening pressure kPa 108 88 128

Overflow valve opening pressure kgf/cm2 1.1 0.9 1.3

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 3.8 3.77 3.83

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 -

Rack position 11.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 79.5 77.9 81.1

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 9+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 16 15 17

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 79.5 78.5 80.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 90 86 94

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.65

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 60 56 64

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

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 1350

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 2.5 2.2 2.8

Remarks
Measure the actual speed, stop

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=M38
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=35.5deg+-3deg b=40.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

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:

Start By:a. remove turbocharger 1. Install the turbocharger on Tool (A).2. Put alignment marks on the two housings and cartridge assembly of the turbocharger for correct alignment during assembly.3. Loosen clamp (3), and remove compressor housing (4) from cartridge assembly (2).4. Loosen the remaining clamp, and remove cartridge assembly (2) from turbine housing (1).
Typical Example5. Put the cartridge group (shown in the illustration) with nut (16) up in Tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (16) that holds the compressor wheel (15) to the wheel assembly (19).6. Remove compressor wheel (15) and housing assembly (6) from wheel assembly (19). Remove piston ring (13) from the wheel assembly.7. Use Tool (C), and remove snap ring (5) from housing assembly (6). Remove insert (14) and sleeve (18) from the housing assembly. Remove seal (22) from insert (14). Remove ring (20) from sleeve (18).8. Remove oil deflector (23), thrust ring (21), bearing assembly (7), spacer sleeve (24) and thrust ring (8) from housing assembly (6).9. Use Tool (D), and remove snap ring (9) from the housing assembly. Remove bearing (25). Remove snap ring (10) with Tool (D).10. Use Tool (D), and remove snap ring (12) from the housing assembly. Remove bearing (26). Remove snap ring (11) with Tool (D).11. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for assembly of the turbocharger.12. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (25) and (26) in housing assembly (6) are installed with the round edge of the outside diameter toward the bearing.
13. Install snap ring (11) with Tool (D). Install bearing (26). Install snap ring (12) with Tool (D).14. Install snap ring (10) with Tool (D). Install bearing (25). Install snap ring (9) with Tool (D).15. Put wheel assembly (19) in position on Tool (B) with the threaded portion end up. Put 6V2055 High Vacuum Grease in the groove for piston ring (13) at assembly to one half or more of the depth of the groove all the way around.16. Install piston ring (13) in the groove in wheel assembly (19).17. Put housing assembly (6) in position on wheel assembly (19).18. Install thrust ring (8) and spacer sleeve (24) on wheel assembly (19).19. Make sure the screen is in place in bearing assembly (7). Install bearing assembly (7) over spacer sleeve (24). Make sure the screen in the bearing assembly is facing toward housing assembly (6) when it is installed.20. Install thrust ring (21) and oil deflector (23)