101601-5802 ZEXEL 9 400 614 629 BOSCH INJECTION-PUMP ASSEMBLY 9400614629 1016015802 220007421a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 629 9400614629

ZEXEL 101601-5802 1016015802

HINO 220007421A 220007421a

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Buy INJECTION-PUMP ASSEMBLY 101601-5802 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5802 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-5310

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0241

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 19.6(220)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-0490

15. NOZZLE SET

Include in #1:

101601-5802 as INJECTION-PUMP ASSEMBLY

Include in #2:

104207-3002 as _

Cross reference number

BOSCH 9 400 614 629 9400614629

ZEXEL 101601-5802 1016015802

HINO 220007421A 220007421a

Zexel num

Bosch num

Firm num

Name

101601-5802

9 400 614 629

220007421A 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 3.07 3.13

Beginning of injection position
Drive 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 -

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 42.4 46.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(8.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 44.4 43.4 45.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 43.5 41.5 45.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 44.1 42.1 46.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 36.2 34.2 38.2

Fixing the lever *

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1600

Advance angle deg. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL
----------
T1=93 RAL=[R1+0.2]+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=55mm
----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-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:

Engine Model View
3408 Engine Shown
Turbochargers (1), Exhaust Outlet (2), Crankcase Breather (3), Lifting Eye (4), Flywheel (5), Magnetic Pickup (6), Electronic Control Module (ECM) (7), Oil Fill Tube (8), Thermostat (9), Primary Fuel Filter (10), Water Pump (11), Crankshaft Vibration Damper (12), Alternator (13), Oil Filters (14), Crankcase Drain Plug (15), Fuel Filters and Priming Pump (16).3408 Engine Description
Caterpillar 3408 electronically controlled Industrial Engines are 18 liter (1099 cu in), 137 mm (5.4 in) bore and 152.4 mm (6.0 in) stroke, four cycle, 8 cylinder, 65 degree vee diesel design. The engine is twin turbocharged with jacket water aftercooling and direct fuel injection. It is designed for petroleum and auxiliary industrial applications.The engine and components are designed for high power output. The reduced size and weight plus increased fuel economy provide maximum performance. Contact your Caterpillar dealer for information on power ratings.Larger diameter plungers and a higher injection rate camshaft are incorporated in the valve train/fuel system. The fuel lines are made of high strength steel and the ends of the lines have collared washers to increase reliability.The cooling system has a gear driven centrifugal water pump, two thermostats (one for each bank) which regulate engine coolant temperature, and an oil cooler. A customer supplied fan drive and cooling system (radiator) may be required for the industrial