101603-2691 ZEXEL 9 400 611 219 BOSCH INJECTION-PUMP ASSEMBLY 9400611219 1016032691 220205740a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 219 9400611219

ZEXEL 101603-2691 1016032691

HINO 220205740A 220205740a

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Buy INJECTION-PUMP ASSEMBLY 101603-2691 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2691 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9231

3. GOVERNOR 105400-8850

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-1180

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5290

11. Nozzle and Holder 23600-3330A

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

13. NOZZLE-HOLDER 105041-5130

14. NOZZLE 105025-2790

15. NOZZLE SET

Include in #1:

101402-0760 as _

101603-2691 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 219 9400611219

ZEXEL 101603-2691 1016032691

HINO 220205740A 220205740a

Zexel num

Bosch num

Firm num

Name

101603-2691

9 400 611 219

220205740A HINO

INJECTION-PUMP ASSEMBLY
W06E K 14BE INJECTION PUMP ASSY PE6A PE

101603-2691

9 400 611 219

S220205740 HINO

INJECTION-PUMP ASSEMBLY
W06E A K 14BE INJECTION PUMP ASSY PE6A 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 3.45 3.42 3.48

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 9.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 45.6 43.6 47.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 310 310 310

Average injection quantity mm3/st. 15 13.5 16.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

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 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=15
----------

Speed control lever angle

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

----------
a=12deg+-5deg b=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=7.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

(1) Fuel pump drive gear (mechanical governor): Diameter of gear bore ... 44.45 to 44.48 mm (1.750 to 1.751 in)Outside diameter of fuel pump hub ... 44.40 to 44.420 mm (1.748 to 1.7488 in)Fuel pump drive gear [hydraulic governor (not shown)]:Diameter of gear bore ... 41.275 to 41.305 mm (1.6250 to 1.6262 in)Outside diameter of gear carrier ... 41.212 to 41.245 mm (1.6225 to 1.6238 in)Running clearance between gear and carrier ... 0.030 to 0.094 mm (0.0012 to 0.0037 in)(2) Camshaft gear: The threads of the removal holes in the camshaft gear have been changed from 5/16 UNF to M8X 1.25. Gears with metric threads have the letter "M" near one of the tapped holes.Diameter of gear bore ... 34.93 to 34.95 mm (1.375 to 1.376 in)Outside diameter of camshaft hub ... 34.902 to 34.917 mm (1.3741 to 1.3747 in)Clearance between gear and camshaft hub ... -0.023 to +0.033 mm (-.0009 to +.0013 in)(3) Torque for camshaft gear bolt ... 70 N m (50 lb ft)(4) Idler gear and hub (with bearing): Inside diameter of gear bearing ... 50.795 to 50.818 mm (1.9998 to 2.0007 in)Outside diameter of gear hub ... 50.700 to 50.737 mm (1.9960 to 1.9975 in)Clearance of gear on hub ... 0.058 to 0.119 mm (0.0023 to 0.0047 in)Idler gear end play ... 0.10 to 0.20 mm (0.004 to 0.008 in)Maximum permissible end play ... 0.25 mm (0.010 in)Idler gear and hub (with needle bearing):Inside diameter of idler gear ... 62.016 to 62.032 mm (2.4414 to 2.4422 in)Outside diameter of bearing ... 69.999 mm (2.4409 in)Clearance between idler gear and bearing ... 0.013 to 0.033 mm (0.0005 to 0.0013 in)Inside diameter of gear bearing ... 55.001 mm (2.1654 in)Outside diameter of gear hub ... 54.988 to 55.001 mm (2.1649 to 2.1654 in)Clearance of gear on hub ... 0.000 to 0.013 mm (0.0000 to 0.0005 in)Idler gear end play ... 0.15 to 0.51 mm (0.006 to 0.020 in)(5) Torque for idler gear bolts ... 40 N m (30 lb ft)(6) Crankshaft gear: Diameter of gear bore ... 47.63 to 47.65 mm (1.875 to 1.876 in)Outside diameter of crankshaft for gear ... 47.630 to 47.638 mm (1.8750 to 1.8755 in)(7) Oil pump idler gear: Diameter of gear bore ... 25.40 to 25.430 mm (1.000 to 1.0012 in)Outside diameter of bearing ... 25.40 to 25.420 mm (1.000 to 1.0008 in)Inside diameter of bearing ... 22.225 to 22.258 mm (0.8750 to 0.8763 in)Outside diameter of idler gear shaft ... 22.192 to 22.205 mm (0.8737 to 0.8742 in)Clearance of gear on shaft ... 0.020 to 0.066 mm (0.0008 to 0.0026 in)Idler gear end play ... 0.05 to 0.41 mm (0.002 to 0.016 in)Timing gear backlash:Minimum ... 0.08 mm (0.003 in)Maximum ... 0.15 mm (0.006 in)