101402-2460 ZEXEL 9 400 613 873 BOSCH INJECTION-PUMP ASSEMBLY 9400613873 1014022460 220206440a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 873 9400613873

ZEXEL 101402-2460 1014022460

HINO 220206440A 220206440a

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Buy INJECTION-PUMP ASSEMBLY 101402-2460 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-2460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9550

3. GOVERNOR 105400-9600

4. SUPPLY PUMP 105220-6580

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-9520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8610

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/21.6(220)

13. NOZZLE-HOLDER 105031-7310

14. NOZZLE

15. NOZZLE SET 105019-2620

Include in #1:

101402-2460 as INJECTION-PUMP ASSEMBLY

101603-2611 as _

Cross reference number

BOSCH 9 400 613 873 9400613873

ZEXEL 101402-2460 1014022460

HINO 220206440A 220206440a

Zexel num

Bosch num

Firm num

Name

101402-2460

9 400 613 873

220206440A HINO

INJECTION-PUMP ASSEMBLY
W04D K 14BD INJECTION PUMP ASSY PE4AD 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 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 83 81 85

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 11.5 10 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position 11++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=12 N1=900r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=80mm
----------
a=26deg+-5deg b=52deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=6.3mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-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:

Table 1
Diagnostic Trouble Codes
J1939 Code and Description CDL Code and Description
4334–20
Aftertreatment #1 DEF #1 Pressure (absolute) : Data Drifted High 3090–20
Aftertreatment #1 DEF Pressure Sensor : Data Drifted High
4334-21
Aftertreatment #1 DEF #1 Pressure (absolute) : Data Drifted Low 3090-21
Aftertreatment #1 DEF Pressure Sensor : Data Drifted Low
3361-5
Aftertreatment #1 DEF Dosing Unit : Current Below Normal 3821-5
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator : Current Below Normal
3361-6
Aftertreatment #1 DEF Dosing Unit : Current Above Normal 3821-6
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator : Current Above Normal
3516-12
Aftertreatment #1 DEF Concentration : Failure 3100-12
Aftertreatment #1 DEF Tank Fluid Quality Sensor : Failure
Table 2
Event Codes
J1939 Code and Description CDL Code and Description
5392-31
Aftertreatment Diesel Exhaust Fluid Dosing Unit Loss of Prime E1370 (2)
Aftertreatment #1 DEF Dosing Unit Loss of Prime
4334-18
Aftertreatment #1 DEF #1 Pressure (absolute) : Low - moderate severity (2) E931 (2)
Low Aftertreatment #1 DEF Pressure
4334-16
Aftertreatment #1 DEF #1 Pressure (absolute) : High - moderate severity (2) E930 (2)
High Aftertreatment #1 DEF Pressure
3516-16
Aftertreatment #1 DEF Concentration : High - moderate severity (2) E1365 (2)
High Aftertreatment #1 DEF Concentration
3516-18
Aftertreatment #1 DEF Concentration : Low - moderate severity (2) E1364 (2)
Low Aftertreatment #1 DEF Concentration
5246-15
Aftertreatment SCR Operator Inducement Severity : High - least severe (1) E1389 (1)
Aftertreatment #1 SCR Operator Inducement
5246-16
Aftertreatment SCR Operator Inducement Severity : High - moderate severity (2) E1389 (2)
Aftertreatment #1 SCR Operator Inducement
5246-0
Aftertreatment SCR Operator Inducement Severity : High - most severe (3) E1389 (3)
Aftertreatment #1 SCR Operator Inducement Ensure that DEF fluid conforms to specification ISO 22241 requirements and fluid handling, filling, and storage procedures are strictly followed.All transfer equipment and storage containers should be used exclusively for DEF and should not be reused for other fluids. For example coolants, fuels, oils, and windshield washer fluid.If contamination of the DEF system is suspected, refer to Troubleshooting, DEF Concentration is Incorrect. Ensure that the correct troubleshooting steps are followed. To test for contamination of the DEF tank, refer to Systems Operation Testing and Adjusting, Diesel Exhaust Fluid Quality - Test.If the DEF is contaminated, Caterpillar recommends that the DEF tank is flushed. Refer to Systems Operation Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush for the correct procedure.