Information injection-pump assembly
BOSCH
9 400 615 066
9400615066
ZEXEL
101603-2800
1016032800
HINO
220206430A
220206430a
Rating:
Service parts 101603-2800 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236003581A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
14.
NOZZLE
Cross reference number
BOSCH
9 400 615 066
9400615066
ZEXEL
101603-2800
1016032800
HINO
220206430A
220206430a
Zexel num
Bosch num
Firm num
Name
101603-2800
9 400 615 066
220206430A HINO
INJECTION-PUMP ASSEMBLY
J08C-T K 14BF INJECTION PUMP ASSY PE6AD PE
J08C-T K 14BF INJECTION PUMP ASSY PE6AD PE
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor 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
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.
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
600--
Advance angle
deg.
0
0
0
Load
0/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0
-0.3
0
Load
0/4
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
-1.5
-1.8
-1.2
Load
0/4
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_05
Pump speed
r/min
800-50
Advance angle
deg.
-1.5
-1.8
-1.2
Load
4/4
Remarks
Finish
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: BCL
(5)Rack difference between N = N1 and N = N2
(6)Idle sub spring setting: L1.
----------
K=15 BCL=0.3+-0.1mm N1=1050r/min N2=500r/min L1=7.8+-0.2mm
----------
----------
K=15 BCL=0.3+-0.1mm N1=1050r/min N2=500r/min L1=7.8+-0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=100mm
----------
a=(7deg)+-5deg b=(23deg)+-5deg
----------
aa=100mm
----------
a=(7deg)+-5deg b=(23deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Stopper bolt setting
(3)Speed = bb, rack position = cc (sealed at delivery)
(4)Normal stop
(5)Stopper bolt setting
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=50deg+-5deg b=13deg+-5deg
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=50deg+-5deg b=13deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
1. Remove oil supply tube (1) and suction bell and tube (2). 2. Remove bolts (3) that hold the oil pump to the cylinder block and remove oil pump (4).3. To install, put oil pump (4) in position on the cylinder block. Install the bolts that hold the oil pump to the cylinder block.4. Put clean engine oil on the O-ring seals of the tubes.5. Install oil supply tube (1), suction bell and tube (2).End By:a. install oil panDisassemble Oil Pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump
Start By:a. remove oil pump 1. Remove the bolt and washer that hold the gear on the shaft.2. Use Tool (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve. Remove the spring and the bypass valve.4. Remove cover (2) from the pump body. 5. Use Tool (B) and remove the bearings from the cover. 6. Remove gears (5) from pump body (4).7. Use Tool (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use Tool (B) to install the bearings in the pump body. Install the bearings so the joint in the bearings is 30 15 degrees from the center line of the oil pump outlet passage (2). 2. Install idler gear and drive gear (5) in the oil pump body (4). Put clean engine oil on the bearings and the gears. 3. Use Tool (A) and install the bearings in cover (2). Install the bearings so the joint of the bearing bores toward oil pump outlet passage (6).4. Install bypass valve (7), spring (8) and the retainer.5. Install the key on the shaft. 6. Install gear (1) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.End By:a. install oil pump
Have questions with 101603-2800?
Group cross 101603-2800 ZEXEL
Hino
101603-2800
9 400 615 066
220206430A
INJECTION-PUMP ASSEMBLY
J08C-T
J08C-T