101601-5860 ZEXEL 9 400 614 632 BOSCH INJECTION-PUMP ASSEMBLY 9400614632 1016015860 220203800a


 

Information injection-pump assembly

BOSCH 9 400 614 632 9400614632
ZEXEL 101601-5860 1016015860
HINO 220203800A 220203800a
101601-5860 INJECTION-PUMP ASSEMBLY
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Service parts 101601-5860 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5100
3. GOVERNOR 105400-7380
4. SUPPLY PUMP 105210-5230
5. AUTOM. ADVANCE MECHANIS 105614-3510
6. COUPLING PLATE 105662-1280
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6280
11. Nozzle and Holder 23600-2133
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105030-4300
14. NOZZLE 105015-8590
15. NOZZLE SET

Include in #1:

101601-5860 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 614 632 9400614632
ZEXEL 101601-5860 1016015860
HINO 220203800A 220203800a


Zexel num
Bosch num
Firm num
Name
101601-5860 
101602-2670 
9 400 614 632 
220203800A  HINO
INJECTION-PUMP ASSEMBLY
H07C-T * 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   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   3.8 3.77 3.83
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   A
Rack position   9.5
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   98.4 96.4 100.4
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.1+-0.5
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Timer adjustment
Pump speed r/min   925--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   875
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1250
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5860
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)SMA RACK LIMIT; RAL (3)Set idle sub-spring (4)Main spring setting (5)Perform governor adjustment at an ambient temperature of at least 15 deg C (rack limit spring is shape memory alloy).
----------
K=12 RAL=9.7+0.2mm
----------

Speed control lever angle

Test data 101601-5860
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=18deg+-5deg

Stop lever angle

Test data 101601-5860
N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb (2)At shipping (3)Contacts normal side pin (4)Clearance from the pin on the normal side: cc
----------
aa=5.1mm bb=0r/min cc=2.5+-0.5mm
----------
a=53deg+-5deg b=51deg+-5deg c=(6deg)

Timing setting

Test data 101601-5860
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Engine Oil Pressure
The sensor utilizes engine oil pressure and engine speed to perform low engine oil pressure detection for diagnostic and annunciation.The graph below illustrates the limits of low engine oil pressure diagnostic and annunciation. The output from the ECM can be used to drive a relay or a lamp to annunciate Low Oil Pressure conditions.
Oil Pressure ParametersLow Oil Pressure Alarm
Oil pressure sensor location.The sensor is mounted in the front of the engine cylinder block with oil lines connected to the switch. Low engine oil pressure closes the switch.The oil pressure switch senses oil pressure at the bearing oil gallery. No resetting procedure is required. Switches may close at 48 to 62 kPa (7 to 9 psi) below actual trip point.Oil Pressure Sensor Failure
When the sensor output is open, shorted to ground or supply, or measured oil pressure reading is out of specification, a sensor failure may have occurred.The ECM will detect the oil pressure sensor failure and through the diagnostic lamp warn the user about the oil pressure sensor failure. The oil pressure related strategies will be disabled. The oil pressure sensor failure will not cause an engine shut down, power derating, or any engine speed change.Speed Sensing Loss Alarm
When the engine speed sensor can no longer sense engine speed, an alarm and diagnostic code entry will occur. If the ECM can not detect any engine speed, the engine will shut down.Manual Fuel Shutoff Lever
Do not use the emergency shutoff control for a normal stopping procedure.
Manual shutdown shaft with lever location.A manual shutdown shaft is provided to override the governor solenoid. This shutdown will only move the fuel control linkage to the fuel OFF position to starve the engine of fuel. It does not shut off the air inlet.Engine Shutoff Controls
Secondary shutoff controls may be electrically, mechanically or hydraulically operated. Familiarize yourself with the types and locations of the shutoff controls, the conditions which cause each control to function, and the resetting procedure required to start your engine.The shutoff controls should be tested every 1000 hours by authorized Caterpillar dealer personnel.Always determine the cause of the shutdown, and have the necessary repairs made before restarting the engine.Shutoff Solenoid Failure
When the shutoff solenoid output is open or shorted to ground or supply, a failure may have occurred.The ECM will detect open or short condition of the shutoff solenoid. If the solenoid is failed "open", the engine will shut down.The shutoff solenoid failure will cause the engine to shut down, but the pilot or service personnel can mechanically reposition the shutoff solenoid and restart the engine.Cold Start Strategy
This feature utilizes the coolant temperature sensor input to improve low temperature engine starting and warm-up. It provides quicker cold starts, smoke cleanup, reduces battery "deep" cycling and extends engine life. The engine timing is fixed at 19.5 degrees. Engine block heaters are provided to maintain minimum engine temperature when the engine is not running.When the coolant temperature is below 60°C (140°F), the cold start strategy is activated using the following parameters

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Group cross 101601-5860 ZEXEL

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101601-5860  

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