Information injection-pump assembly
BOSCH
9 400 611 596
9400611596
ZEXEL
101603-2493
1016032493
HINO
220205200B
220205200b
Rating:
Service parts 101603-2493 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-3111A
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
101603-2493
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1251
as _
Cross reference number
BOSCH
9 400 611 596
9400611596
ZEXEL
101603-2493
1016032493
HINO
220205200B
220205200b
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.1
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
66.7
66.7
Boost pressure
mmHg
500
500
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
300
300
300
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
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
9.1
Boost pressure
kPa
37.3
36
38.6
Boost pressure
mmHg
280
270
290
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
10.1
Boost pressure
kPa
56
52
60
Boost pressure
mmHg
420
390
450
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
6
5.7
6.3
Remarks
Finish
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)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=10 BCL=1+-0.1mm
----------
----------
K=10 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=34deg+-5deg
----------
----------
a=18deg+-5deg b=34deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
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)
----------
----------
a=(50deg)
Information:
1. Remove two bolts (4) that hold tube assembly (1) to the engine block.2. Remove one bolt (not shown) that holds pipe (3) to oil pump (2). Remove the pipe and tube assembly as a unit. 3. Remove three bolts (5). Remove oil pump (2).Install Oil Pump
1. Check the O-ring seals for damage. If damaged, use new parts for replacement. 2. Put oil pump (1) in position. Install the three bolts that hold the oil pump to the engine. 3. Put clean engine oil on all O-ring seals, and install pipe (2) and tube assembly (3) in the oil pump as a unit. Install two bolts that fasten the pipe assembly to the engine block.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use Tooling (A) to remove drive gear (1) from the shaft. Remove the key from shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use Tooling (B) to remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use Tooling (B) to remove the bearings from the pump body.Assemble Oil Pump
1. Use Tooling (A) to install the bearings in the main pump body until they are even with the outside surface of the pump body. Install the bearings so the junctions in the bearings are 30 15 degrees from the center of the bearing bores and toward the oil pump outlet passage (2) as shown. 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and gears. 3. Use Tooling (A) to install the bearings in cover (4) until they are even with the outside surface of the cover. Install the bearings so the junctions in the bearings are 30 15 degrees from the center of the bearing bores and toward the oil pump outlet passage as shown. 4. Install bypass valve (5), spring (6), spacer and the retainer in the pump body.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that holds the gear on the shaft. Tighten the bolt to a torque of 55 7 N m (41 5 lb ft).7. Make sure the pump turns freely by hand after it is assembled.End By:a. install oil pump
1. Check the O-ring seals for damage. If damaged, use new parts for replacement. 2. Put oil pump (1) in position. Install the three bolts that hold the oil pump to the engine. 3. Put clean engine oil on all O-ring seals, and install pipe (2) and tube assembly (3) in the oil pump as a unit. Install two bolts that fasten the pipe assembly to the engine block.End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use Tooling (A) to remove drive gear (1) from the shaft. Remove the key from shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use Tooling (B) to remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use Tooling (B) to remove the bearings from the pump body.Assemble Oil Pump
1. Use Tooling (A) to install the bearings in the main pump body until they are even with the outside surface of the pump body. Install the bearings so the junctions in the bearings are 30 15 degrees from the center of the bearing bores and toward the oil pump outlet passage (2) as shown. 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and gears. 3. Use Tooling (A) to install the bearings in cover (4) until they are even with the outside surface of the cover. Install the bearings so the junctions in the bearings are 30 15 degrees from the center of the bearing bores and toward the oil pump outlet passage as shown. 4. Install bypass valve (5), spring (6), spacer and the retainer in the pump body.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that holds the gear on the shaft. Tighten the bolt to a torque of 55 7 N m (41 5 lb ft).7. Make sure the pump turns freely by hand after it is assembled.End By:a. install oil pump