Information injection-pump assembly
BOSCH
9 400 615 061
9400615061
ZEXEL
101603-2701
1016032701
HINO
220205780A
220205780a
Rating:
Include in #1:
101492-0161
as _
Cross reference number
BOSCH
9 400 615 061
9400615061
ZEXEL
101603-2701
1016032701
HINO
220205780A
220205780a
Zexel num
Bosch num
Firm num
Name
101603-2701
9 400 615 061
220205780A HINO
INJECTION-PUMP ASSEMBLY
H07C-T K
H07C-T K
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
10.6
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
108.5
107
110
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
455
455
455
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.
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.
130
130
140
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
9.15
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
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
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1000
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
1.5
1.2
1.8
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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: BCL
----------
K=7 BCL=(1.45)mm
----------
----------
K=7 BCL=(1.45)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=100mm
----------
a=(1deg)+-5deg b=(19deg)+-5deg
----------
aa=100mm
----------
a=(1deg)+-5deg b=(19deg)+-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:
Transmission Oil Cooler
The machine is equipped with a power shift transmission. A transmission oil cooler is installed in the outlet section of the radiator. The radiator coolant flows around the tubes of the cooler and cools the transmission oil as it flows through the cooler. The transmission oil then returns to the transmission inlet.Lubrication System
Oil Pump
(1) Strainer. (2) Oil pump relief valve. (3) Oil pump. (4) Idler gear. (5) Crankshaft gear.The lubrication system is the pressure type and the flow of oil goes from the oil pan through strainer (1) into oil pump (3). Oil pump (3) is driven by crankshaft gear (5) through the idler gear (4). The oil pump is connected to the front main bearing cap. Relief valve (2) which is spring loaded controls the maximum oil pressure. An oil pressure sending unit is connected to the main oil gallery.Oil under pressure goes from the oil pump through the relief valve, oil filter and into the main oil gallery that is a drilled passage the length of the crankcase. From the gallery the oil flows through drilled passages to the main bearing bores and then through the crankshaft passages to the big end (rod) bearings. The small end (rod) bearings, cylinder liners and pistons get splash lubrication from the big end (rod) bearings.The camshaft front bearing and journals are lubricated from numbers 1, 3 and 5 main bearings. The camshaft center journal supplies a controlled amount of oil to the rocker shaft assembly. Oil from the rocker shaft drains through a bleed hole in each rocker lever to lubricate the valves, guides, tappets (valve lifters) and cam lobes.
Timing Gears
(6) Idler gear. (7) Idler gear retainer plate.Oil also goes from the gallery through the rear of idler gear (6) hub, then through passages to lubricate the idler gear bearing and gear retainer plate (7). On engines equipped with hydraulic governed fuel injection pumps, the fuel pump adapter plate is also lubricated from the main oil gallery. The timing gears are splash lubricated from the idler gear hub.
Oil Lubrication SchematicAir Inlet And Exhaust System
Air Inlet Components
(1) Intake manifold. (2) Exhaust manifold.
Air Inlet Components
(3) Air cleaner.The air inlet and exhaust system components are: air cleaner (3), intake manifold (1), an air inlet hose, an air indicator, the cylinder head valves and valve mechanism components, exhaust manifold (2), pipe and muffler.Air is pulled in the air inlet system by the intake stroke of the piston. The air flows in air cleaner (3), through air inlet hose that directs the volume of air to intake manifold (1). The air flows through intake manifold (1) which directs even distribution of the air to each cylinder where the air is mixed with fuel from the injectors. The sequence and action of the engines' four cylinders and four strokes, (compression, power, exhaust and intake) give constant air flow to the intake system for engine operation.An air indicator located on the air inlet hose shows a red indication when too much air restriction (dirt)
The machine is equipped with a power shift transmission. A transmission oil cooler is installed in the outlet section of the radiator. The radiator coolant flows around the tubes of the cooler and cools the transmission oil as it flows through the cooler. The transmission oil then returns to the transmission inlet.Lubrication System
Oil Pump
(1) Strainer. (2) Oil pump relief valve. (3) Oil pump. (4) Idler gear. (5) Crankshaft gear.The lubrication system is the pressure type and the flow of oil goes from the oil pan through strainer (1) into oil pump (3). Oil pump (3) is driven by crankshaft gear (5) through the idler gear (4). The oil pump is connected to the front main bearing cap. Relief valve (2) which is spring loaded controls the maximum oil pressure. An oil pressure sending unit is connected to the main oil gallery.Oil under pressure goes from the oil pump through the relief valve, oil filter and into the main oil gallery that is a drilled passage the length of the crankcase. From the gallery the oil flows through drilled passages to the main bearing bores and then through the crankshaft passages to the big end (rod) bearings. The small end (rod) bearings, cylinder liners and pistons get splash lubrication from the big end (rod) bearings.The camshaft front bearing and journals are lubricated from numbers 1, 3 and 5 main bearings. The camshaft center journal supplies a controlled amount of oil to the rocker shaft assembly. Oil from the rocker shaft drains through a bleed hole in each rocker lever to lubricate the valves, guides, tappets (valve lifters) and cam lobes.
Timing Gears
(6) Idler gear. (7) Idler gear retainer plate.Oil also goes from the gallery through the rear of idler gear (6) hub, then through passages to lubricate the idler gear bearing and gear retainer plate (7). On engines equipped with hydraulic governed fuel injection pumps, the fuel pump adapter plate is also lubricated from the main oil gallery. The timing gears are splash lubricated from the idler gear hub.
Oil Lubrication SchematicAir Inlet And Exhaust System
Air Inlet Components
(1) Intake manifold. (2) Exhaust manifold.
Air Inlet Components
(3) Air cleaner.The air inlet and exhaust system components are: air cleaner (3), intake manifold (1), an air inlet hose, an air indicator, the cylinder head valves and valve mechanism components, exhaust manifold (2), pipe and muffler.Air is pulled in the air inlet system by the intake stroke of the piston. The air flows in air cleaner (3), through air inlet hose that directs the volume of air to intake manifold (1). The air flows through intake manifold (1) which directs even distribution of the air to each cylinder where the air is mixed with fuel from the injectors. The sequence and action of the engines' four cylinders and four strokes, (compression, power, exhaust and intake) give constant air flow to the intake system for engine operation.An air indicator located on the air inlet hose shows a red indication when too much air restriction (dirt)
Have questions with 101603-2701?
Group cross 101603-2701 ZEXEL
Hino
101603-2701
9 400 615 061
220205780A
INJECTION-PUMP ASSEMBLY
H07C-T
H07C-T