101602-2510 ZEXEL 9 400 614 778 BOSCH INJECTION-PUMP ASSEMBLY 9400614778 1016022510 220203540a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 778 9400614778

ZEXEL 101602-2510 1016022510

HINO 220203540A 220203540a

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101602-2510 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2510 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3400

3. GOVERNOR 105400-6280

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4303

11. Nozzle and Holder 23600-1171

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-4341

14. NOZZLE

105015-3850

15. NOZZLE SET

Include in #1:

101602-2510 as INJECTION-PUMP ASSEMBLY

Include in #2:

104278-1190 as _

Cross reference number

BOSCH 9 400 614 778 9400614778

ZEXEL 101602-2510 1016022510

HINO 220203540A 220203540a

Zexel num

Bosch num

Firm num

Name

101602-2510

9 400 614 778

220203540A HINO

INJECTION-PUMP ASSEMBLY
EL100 * K 14BF PE6AD 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 4.85 4.8 4.9

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 7.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 82 80.4 83.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 4.4+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Idle sub spring setting: L1.
----------
K=4 RAL=14+0.2mm L1=4.5+-0.2mm
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=38deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Illustration 6 g06613192
Gray locking wedge removed from ECM connector
Remove gray locking wedge from 86-pin connector to provide access to release the DT Pins.Note: Circuit U937 to be removed from pin location number 24 and transferred to pin location 73.Note: Cloth tape will need to be removed to the split in the harness main bundle.Note: The U937 wire can then be routed into the opposite branch to gain enough free length to make the connection.Note: The U939 wire removed from pin location 73 has adequate length to be loaded into location 16.
Transfer and relocate the wires as detailed in Table 2.
Reinstall the locking wedge (B) when all wires have been transferred and relocated.
Illustration 7 g06613197
View of back of ECM connector with connector cover (D) removed
Apply cloth tape to both wire branches from the main bundle of wires up the branches to the harness strain relief strap location.
Illustration 8 g06613199
Connector cover (D) reinstalled with harness secured
(1) 3S-2093 Cable Strap
(D) Connector cover
Reinstall connector cover (D) and secure the harness branches using two cable straps (1).
Use caution when re-engaging the connector with the ECM.
Tighten allen head screw (A).Note: In certain cases, U937 may require lengthening to provide adequate strain relief when relocated in pin 73.Note: Refer to "Soldered Splice","Deutsch connector", or "Sealed Mechanical Splice" for the proper way to extend circuit U937.Soldered Splice
A soldered spliced can be made to extend the wire. Soldered connection will need to be insulated using an appropriately sized adhesive head shrink sleeve.
Illustration 9 g06613210
U937 removed
Remove U937 from ECM connector.
Cut pin off end of wire.
Strip wire 7.5 mm (0.30 inch).
Illustration 10 g06613213
Additional wire soldered to circuit U937
Solder to additional wire to extend U937 and install appropriate sized adhesive head shrink sleeve.
Install pin on end of U937.
Insert U937 into pin 73.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector.Deutsch connector
Table 3
Required Parts
Qty Part Number Part Name
1 115-8109 Wire Splice Note: The deutsch connector is a field serviceable alternative to permanent splices. It is made from the same high-quality silicone elastomer as used for the Deutsch connector seals and grommets. The splice body houses a contact retention system that secures a mated pair of contacts in a compact environmentally sealed unit. This splice can also be serviced with standard deutsch connector tools.
Illustration 11 g06613218
Deutsch connector section view
Illustration 12 g06613221
Deutsch connector splice installed
Illustration 13 g06613224
Sufficient strain relief for deutsch connector
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connectorSealed Mechanical Splice
Table 4
Required Parts
Qty Part Number Part Name
1 136-4877 Wire Splice Note: Sealed mechanical splices have head-shrinkable, environmentally sealed sleeves.
Illustration 14 g06613205
Sealed mechanical splice
Select appropriate splice size.
Strip wire 7.5 mm (0.3 inch).
Insert stripped wire into sealed mechanical splice.
Crimp sealed mechanical splice.
Apply heat to the crimped splice until tubing re-covers and adhesive flows.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector