101602-2153 ZEXEL 9 400 614 754 BOSCH INJECTION-PUMP ASSEMBLY 9400614754 1016022153 220202013a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 754 9400614754

ZEXEL 101602-2153 1016022153

HINO 220202013A 220202013a

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Buy INJECTION-PUMP ASSEMBLY 101602-2153 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2153 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9821

3. GOVERNOR 105400-2990

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-4821

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder 23600-1593A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-5640

15. NOZZLE SET

Include in #1:

101602-2153 as INJECTION-PUMP ASSEMBLY

106671-4534 as _

Cross reference number

BOSCH 9 400 614 754 9400614754

ZEXEL 101602-2153 1016022153

HINO 220202013A 220202013a

Zexel num

Bosch num

Firm num

Name

101602-2153

9 400 614 754

220202013A HINO

INJECTION-PUMP ASSEMBLY
W06D * 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 131424-5720

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 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 3.1 3.05 3.15

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 34.6 31.6 37.6

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.4

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 46.4 44.4 48.4

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 8.2 6.7 9.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 105

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=5
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=32deg+-3deg b=(14deg)+-5deg c=(5deg)+-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:

Determine the fuel rail pressure and the injector test engine speed (where the peak pressure was selected). Typically, pressure will start building after 2 to 5 seconds and then there should be sampling for 5 more seconds. Illustration 7 shows an example of selecting the peak pressure and corresponding speed.
Calculate the speed change of the injector test as follows:Injector test speed change equals injector test engine speed minus pump test engine speed.
Determine injector pressure correction using the injector test speed change and Table 5. This will correct for pressure change as speed changes.
Table 5
Injector Pressure Correction Based on Speed Change
Engine speed change (rpm) 0-5 6-10 11-15 16-20 21-25 26-30 31-35
Six-cylinder pressure correction 283 kPa (41 psi) 896 kPa (130 psi) 1455 kPa (211 psi) 2013 kPa (292 psi) 2572 kPa (373 psi) 3130 kPa (454 psi) 3689 kPa (535 psi)
Four-cylinder pressure correction 159 kPa (23 psi) 510 kPa (74 psi) 834 kPa (121 psi) 1151 kPa (167 psi) 1469 kPa (213 psi) 1793 kPa (260 psi) 2110 kPa (306 psi)
If the injector test engine speed is lower than pump test engine speed, then correct the injector pressure by adding the correction as follows:Injector corrected pressure equals injector test pressure plus injector pressure correction.
If the injector test engine speed is higher than pump test engine speed (as can happen when a battery booster is used), then correct the injector test pressure by subtracting the pressure correction as follows:Injector corrected pressure equals injector test pressure minus injector pressure correction.
Calculate injector leakage ratio as follows:Injector leakage ratio equals injector corrected pressure divided by pump test rail pressure.If the Injector leakage ratio is less than 0.85, the injector must be replaced, if the injector leakage is greater than 0.85 the injector is within the required parameters.Remove the fuel line. Replace the cap on the fuel manifold (rail) and injector.
Proceed to the next injector to be checked. Repeat Step 1 through Step 8 for the remaining electronic unit injectors to be tested.
Remove components of 362-9754 Test Kit from the engine. Replace any fuel injection lines that were removed during the procedures. Refer to Disassembly and Assembly, Fuel Injection Lines - Install for the correct procedure.
Reconnect the electronic unit injector harness connectors.Test Kit Data Sheet
Table 6
Fuel Injection Pump Tests Pump Test Rail Pressure Pump Test Engine Speed Minimum Cranking Pressure (MCP) Service
From Pump Test Datalog From Pump