101603-2650 ZEXEL 9 400 611 256 BOSCH INJECTION-PUMP ASSEMBLY 9400611256 1016032650 220205650a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 256 9400611256

ZEXEL 101603-2650 1016032650

HINO 220205650A 220205650a

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Buy INJECTION-PUMP ASSEMBLY 101603-2650 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2650 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5431

3. GOVERNOR 105401-1100

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105672-0470

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:

101603-2650 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6930 as _

Cross reference number

BOSCH 9 400 611 256 9400611256

ZEXEL 101603-2650 1016032650

HINO 220205650A 220205650a

Zexel num

Bosch num

Firm num

Name

101603-2650

9 400 611 256

220205650A 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 10.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 106 104.5 107.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 420 420 420

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 E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

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 R1-1.45

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10.6)

Boost pressure kPa 22.7 16 29.4

Boost pressure mmHg 170 120 220

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)Boost compensator stroke
----------
K=7
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=100mm
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a=4deg+-5deg b=22deg+-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
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a=21deg+-5deg b=(55deg)

0000001501 RACK SENSOR

(g) rack limit (h) rack sensor performance confirmation position (i) pump end face (j) Apply red paint. Rack sensor adjustment (-5*20, threaded type, with A type rack limiter) 1. Rack limit adjustment (1)When installing joint (b), select a shim (d) so that the rack limit rack position is Rb and the injection quantity is Qa. (2)Install rod (E) to the rack (c). (3)Select a joint (b) from the table above so that the distance from the pump end face to the rod (e) is L - 0.2 mm at rack position Rb. 2. Rack sensor adjustment (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the lever and set the pump speed at N1 and the rack position at Ra. (3)Adjust the amount that the bobbin (a) is screwed in so that the amp's output voltage is V1. Then, fix using nut (f). (4)Set the lever at the full speed side and confirm that the amp's output voltage is V1. (5)Stick the caution plate on the top of the joint and apply red paint to the joint (b) and nut (f) join, and to the pump end face and joint (b) join. Speed N1, Rack position = Ra, output voltage V1+-0.01 (V), rack sensor supply voltage 5+-0.01 (V)
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Qa=135+10mm3/st Ra=10.6mm N1=1100r/min V1=2.5+-0.01V
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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:

3. Remove bearing caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft. 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pistons (2). Keep each cap with the respective connecting rod.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed. Do not damage the cooling tubes when the pistons are removed.
Install Pistons
1. Put clean engine oil on the piston rings, connecting rod bearings and cylinder liners. 2. Put two pistons in position opposite of each other in the correct bore of the block. install pistons (1) with Tool (A).
Be sure the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.
For more detail about installation of connecting rod bearings, see remove and install connecting rod bearings.3. Check the bearing clearance with Plastigage (B).
Do not use an impact wrench to tighten the nuts the additional 120 degrees.
4. Put clean engine oil on bolts (5). Install caps (3) and nuts finger tight. Tighten each nut to a torque of 80 8 N m (60 6 lb ft). Put a mark across the nuts and bolts. Tighten each nut 120 degrees more.5. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be 0.28 to 0.84 mm (.011 to .033 in) for new rods.End By:a. install oil pumpb. install cylinder headsDisassemble & Assemble Pistons
Start By:a. remove pistons 1. Remove bearing halves (2) from the connecting rod and connecting rod cap. New retainer rings allow the use of pliers to remove retainer rings (1).2. Use Tool (C) or pliers to remove retainer rings (1) from each side of the piston. Remove pin (3) and the connecting rod from the piston. 3. Use Tool (A) to remove the piston rings from piston (4). 4. Heat the connecting rod to a temperature of 177° - 204°C (350° - 400°F). Put 5P-8651 Spacer (12) in the base plate. Put connecting rod in position on the base plate of Tooling (B).5. Put the connecting rod piston pin bearing end in the center of the port assembly of Tooling (B). Install pin (8) in the center of the bore for the connecting rod bearings.6. Install 5P-8650 adapter (10). Put the hole in the adapter in alignment with the hole in the base plate of Tooling (B).7. Install clamp bar (11) and clamp pin (7).8. Install new piston pin bearing (6) on adapter (10). The old bearing is pushed out by Tooling (B) as the new bearing is installed.9. Put 5P8649 Adapter (9) in position as shown with the taper side down. The piston pin bearing joint must be in alignment with the hole in adapter (10) and the base plate of Tooling (B).10. Put pusher (5) on adapter (9).11. Use Tooling (B) to push