101603-2502 ZEXEL 9 400 611 326 BOSCH INJECTION-PUMP ASSEMBLY 9400611326 1016032502 220205222a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 326 9400611326

ZEXEL 101603-2502 1016032502

HINO 220205222A 220205222a

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Buy INJECTION-PUMP ASSEMBLY 101603-2502 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2502 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6590

3. GOVERNOR 105419-2781

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105672-5450

6. COUPLING PLATE 105663-0970

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8470

11. Nozzle and Holder 23600-3290A

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE 105025-1770

15. NOZZLE SET

Include in #1:

101402-0751 as _

101603-2502 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 326 9400611326

ZEXEL 101603-2502 1016032502

HINO 220205222A 220205222a

Zexel num

Bosch num

Firm num

Name

101603-2502
101603-2503

9 400 611 326

220205222A HINO

INJECTION-PUMP ASSEMBLY
J08C-H * K 14BF 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 131425-0620

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.8 3.77 3.83

Beginning of injection position
Governor 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 9.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92 90 94

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 395 395 395

Average injection quantity mm3/st. 9.5 8.5 10.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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. 120 120 130

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

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)Set idle sub-spring (5)Main spring setting
----------
K=14
----------

Speed control lever angle

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

----------
a=28deg+-5deg b=13deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb (2)Normal
----------
aa=5.8mm bb=0r/min
----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(20deg)

Information:

1. Remove plug (1) from the fuel injection pump housing.2. Use Tool (D) to loosen nut (2) for the fuel injection pump to be removed. Disconnect the fuel injection line nuts, and remove the felt washer. 3. Install Tool (A) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on Tool (A) while the control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position.4. Use Tool (B) to remove bushing (3) from the fuel injection pump housing. 5. Remove bushing (3) and O-ring seal (4).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
6. Use Tool (C) to remove fuel injection pump (5). 7. Remove spacer (6) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. Do not remove or make any adjustments of the gear segment on the plunger. It has been preset at the factory. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
8. Disassemble the fuel injection pump as follows: Remove ring (7). Separate bonnet (10) from barrel (9). Remove the spring and the check assembly from the bonnet. Remove plunger (8), the washer and spring from barrel (9).Install Fuel Injection Pumps
1. Inspect all parts for wear or damage. The plunger and barrel are serviced only as an assembly. 2. Put clean diesel fuel on plunger (1). Put plunger (1), washer (6) and spring (2) in position on barrel (3).3. Put check valve assembly (7) and spring (8) in bonnet (9). Connect bonnet (9) and barrel (3) together with ring (4). 4. Put spacer (10) into position in the pump housing bore. Be sure the correct spacer is with each pump. 5. Note the location of dowels (11) and (12) in the fuel injection pump housing. These dowels are for alignment of the fuel injection pump. 6. Slot (13) in gear segment (5) must align with dowel (11).7. Groove (14) must engage with dowel (12). 8. Use Tool (A) to put the fuel racks in the center (zero) position. See Remove Fuel Injection Pumps.9. Use Tool