101603-2671 ZEXEL 9 400 612 495 BOSCH INJECTION-PUMP ASSEMBLY 9400612495 1016032671 220205680a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 495 9400612495

ZEXEL 101603-2671 1016032671

HINO 220205680A 220205680a

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Buy INJECTION-PUMP ASSEMBLY 101603-2671 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2671 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5431

3. GOVERNOR 105401-1130

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105672-0790

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:

101603-2671 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6960 as _

Cross reference number

BOSCH 9 400 612 495 9400612495

ZEXEL 101603-2671 1016032671

HINO 220205680A 220205680a

Zexel num

Bosch num

Firm num

Name

101603-2671

9 400 612 495

220205680A 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 10.8

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 142.5 141 144

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point C

Rack position 5.9+-0.5

Pump speed r/min 435 435 435

Average injection quantity mm3/st. 8.5 7.5 9.5

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. 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 600 600 600

Rack position R1-1.4

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(10.8)

Boost pressure kPa 24 17.3 30.7

Boost pressure mmHg 180 130 230

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 950

Advance angle deg. 0.7 0.4 1

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: 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=13
----------

Speed control lever angle

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

----------
a=(5deg)+-5deg b=(17deg)+-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)

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:

Cylinder Heads Without Guides Cylinder Heads With Guides New cylinder heads have been introduced on the 4.236 engine. The new heads have replaceable valve guides. The differences between the earlier and current heads are explained below. The change became effective at engine number LD---U040236M and up. See General Information in Systems Operation for the engine serial number location.Double valve springs:(1) Outer spring: Length under test force ... 45.22 mm (1.780 in)Test force ... 178 9 N (40 2 lb)(Damper coils of spring go toward cylinder head).(2) Inner spring: Length under test force ... 39.70 mm (1.563 in)Test force ... 69 4 N (15.4 1 lb)(Damper coils of spring go toward cylinder head).Single valve springs (not shown). Length under test force ... 41.4 mm (1.63 in)Test force ... 251 13 N (56.4 3 lb)(No damper coils).Cylinder Heads Without Removable Guides
(3) Exhaust valve stem diameter ... 9.449 to 9.469 mm (0.372 to 0.3728 in) Valves are available in stem oversizes of 0.08, 0.38 and 0.76 mm (0.003, .015 and .030 in).Exhaust valve overall length ... 123.11 to 123.52 mm (4.847 to 4.863 in)Bore in cylinder head for valve ... 9.506 to 9.531 mm (0.3743 to 0.3752 in)Clearance between valve stem and bore ... 0.0368 to 0.0826 mm (0.00145 to 0.00325 in)Maximum permissible clearance between valve stem and bore ... 0.15 mm (0.006 in)(4) Intake valve stem diameter ... 9.462 to 9.487 mm (0.3725 to 0.3735 in) Valves are available in stem oversizes of 0.08, 0.38, and 0.76 mm (0.003, .015 and .030 in).Intake valve overall length ... 122.71 to 123.11 mm (4.831 to 4.847 in)Bore in cylinder head for valve ... 9.506 to 9.531 mm (0.3743 to 0.3752 in)Clearance between valve stem and bore ... 0.0191 to 0.0699 mm (0.00075 to 0.00275 in)Maximum permissible clearance between valve stem and bore ... 0.13 mm (0.005 in)Cylinder Heads With Removable Guides
(5) Valve guides: Inside diameter ... 9.53 to 9.55 mm (0.375 to 0.376 in)Outside diameter ... 15.900 to 15.913 mm (0.6260 to 0.6265 in)Parent bore diameter in cylinder head for valve guide ... 15.875 to 15.888 mm (0.6250 to 0.6255 in)Interference fit of guide in cylinder head ... 0.005 to 0.046 mm (0.0002 to 0.0018 in)Overall length of guide:Intake ... 57.94 mm (2.281 in)Exhaust ... 61.913 mm (2.4375 in)Projection of guide above valve spring recess ... 15.09 mm (0.594 in)(6) Exhaust valve stem diameter ... 9.449 to 9.468 mm (0.3720 to 0.3728 in) Clearance of valve in guide ... 0.058 to 0.102 mm (0.0023 to 0.0040 in)Maximum