101603-2781 ZEXEL 9 400 615 065 BOSCH INJECTION-PUMP ASSEMBLY 9400615065 1016032781 220206350b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 065 9400615065

ZEXEL 101603-2781 1016032781

HINO 220206350B 220206350b

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101402-0853 as _

Cross reference number

BOSCH 9 400 615 065 9400615065

ZEXEL 101603-2781 1016032781

HINO 220206350B 220206350b

Zexel num

Bosch num

Firm num

Name

101603-2781
101603-2782

9 400 615 065

220206350B HINO

INJECTION-PUMP ASSEMBLY
J08C-T * K

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 11.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 133.5 131.5 135.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 34 34

Boost pressure mmHg 255 255

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

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 11.6++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 100 110

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.4

Boost pressure kPa 18 15.3 20.7

Boost pressure mmHg 135 115 155

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.7

Boost pressure kPa 20.7 20.7 20.7

Boost pressure mmHg 155 155 155

Timer adjustment

Pump speed r/min 0

Advance angle deg. 0 0 0

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min 800-50

Advance angle deg. -1.5 -1.8 -1.2

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)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Idle sub spring setting: L1.
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K=15 N1=1050r/min N2=500r/min L1=7.8+-0.2mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=100mm
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a=(7deg)+-5deg b=(23deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position = aa, speed = bb (stamp at delivery) (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
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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=(20deg)

Information:

2. Loosen two hose clamps (1).3. Remove hose (2). 4. Remove two bolts (3).5. Remove elbow (5).6. Remove fumes disposal tube (4) for access to the water pump.7. Disconnect coolant conditioner hose (6).8. Remove heater hose (12) (previously removed).9. Loosen hose clamp (15).10. Disconnect lower radiator hose (13).11. Remove two bolts (14) from oil cooler. Check gasket for wear or damage. Replace if necessary.12. Remove four bolts (10).13. Remove water pump cover (11).14. Remove seven long bolts (7).15. Reposition air conditioning lines and oil line (8) after bolts are removed.16. Remove water pump (9). Check seals and O-rings for wear and damage before installation, replace as necessary. For installation of the water pump, reverse the removal steps.17. Fill the cooling system with coolant to correct level. See the Operation & Maintenance Manual.Disassemble Water Pump
*Part of 1P510 Driver Group.Start By:a. remove water pump The water pump seal can be replaced without removing the water pump from the engine. An intermittent leakage of a small amount of coolant from the hole in the water pump housing is not an indication of a water pump seal failure. This is required to provide lubrication for the seal. Replace the water pump seal only if a large amount of leakage or a constant flow of coolant is observed draining from the water pump housing.1. Remove O-ring seal (1) from the adapter.2. Remove adapter (2) from the housing. Remove the O-ring seal from the outside diameter of the adapter.3. Remove bolt (3) and the retainer that hold the impeller on the shaft. 4. Use Tool (A) to remove impeller (4) from the shaft. 5. Remove the spring and seal (5) from the shaft. 6. Remove four bolts (7) from retainer (6) that hold the shaft assembly to the pump housing.7. Remove O-ring seal (8) from the housing. 8. Remove gear and shaft assembly (10) from the housing.9. Remove bolt (9) and the retainer from the shaft assembly. 10. Use a press to remove the shaft assembly from gear (11). Remove the retainer from the shaft assembly. 11. Remove bearing (13), spacer (14) and bearing (12) from the shaft. 12. Remove lip-type seal (15) from the housing.13. Turn the housing over, and remove ceramic ring (16) and the seal.Assemble Water Pump
1. Use 6V1541 Quick Cure Primer to clean shaft (8) and the seal counterbore in the pump housing.2. Install bearing (4), spacer (3) and bearing (2) on shaft (8).3. Put retainer (1) and gear (7) in position on the shaft assembly. Install retainer (6) and bolt (5). 4. Use Tool (A) to install the lip-type seal in the housing as shown. Put a small amount of clean SAE 30 Oil on the lip of the seal. 5. Install a new O-ring seal (10) on the housing.6. Put shaft assembly (9) in position in the housing. Install the bolts that hold the retainer to the housing.
Clean water only is permitted for use as a lubricant for assistance at installation. Do not damage or put hands on