101602-2492 ZEXEL 9 400 614 776 BOSCH INJECTION-PUMP ASSEMBLY 9400614776 1016022492 220203651b


 

Information injection-pump assembly

BOSCH 9 400 614 776 9400614776
ZEXEL 101602-2492 1016022492
HINO 220203651B 220203651b
101602-2492 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101602-2492 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2492 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9940
3. GOVERNOR 105400-6221
4. SUPPLY PUMP 105220-5140
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156636-4821
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-4230
11. Nozzle and Holder 23600-1580
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105041-5030
14. NOZZLE 105015-5160
15. NOZZLE SET

Include in #1:

101602-2492 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 614 776 9400614776
ZEXEL 101602-2492 1016022492
HINO 220203651B 220203651b


Zexel num
Bosch num
Firm num
Name
101602-2492 
9 400 614 776 
220203651B  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   9.5
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   45.6 43.6 47.6
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   9.7
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   43.7 40.7 46.7
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   7.8+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   9 7.5 10.5
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_04
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   63 63 73
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101602-2492
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
----------
K=11
----------

Speed control lever angle

Test data 101602-2492
F:Full speed I:Idle (1)Set the speed at aa, set the stopper bolt (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(2deg)+-5deg b=(15deg)+-5deg c=(5deg)+-5deg

Stop lever angle

Test data 101602-2492
N:Pump normal S:Stop the pump. (1)Distance from normal side pin = aa. (2)At shipping: rack position = bb or less, speed = cc. (3)Contacts normal side pin
----------
aa=2.5+-0.5mm bb=6.9mm cc=0r/min
----------
a=27deg+-5deg b=53deg+-5deg c=(6deg)

Timing setting

Test data 101602-2492
(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:


Illustration 39 g03157737
Select "Engine Technical Marketing Information - TMI Web" under the "Additional Service Information" heading.Note: If "Engine Technical Marketing Information - TMI Web" is not visible, select "View More".
Illustration 40 g03817877
Input the serial number of the engine in "Reference Number" box (1).
Select "Serial Number" in drop-down menu (2).
Select "Retrieve Data" (3).
Illustration 41 g03817327
Select "Emissions Data" (4).
Select "Need emissions replacement label? Click here!" (5).Note: "Large Power Systems Division" window will now open.
Illustration 42 g03817878
Select "Recon Replacement Request".
Illustration 43 g03818933
Typical example - "Emissions/Certification Replacement" window
Fill in the required details:
Table 5
Emissions/Certification Replacement Window
Item Description
2 Enter the dealer name (code)
3 Enter "Machine"
4 Enter "C15" under Engine Sales Model
5 Enter the Engine Serial Number
6 Enter the media number of the Special Instruction
When all details are filled in, select "Submit".Note: Two labels and a serial number plate will be sent to the dealer address. If two labels are not received, contact Global_Engine_Marking.
Illustration 44 g03159376
Install the new emissions certification film (6), information label (7), and serial number plate on the cylinder block according to the installation instructions received with the labels and plate.Note: Destroy the old emissions certification film and serial number plate.Operation and Maintenance information
There are several specific messages on this machine. The exact location of the messages and the description of the messages are reviewed in this section. Become familiarized with all messages.Make sure that all of the messages are legible. Clean the messages or replace the messages if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. Loose adhesive will allow the messages to fall.Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Any Cat® dealer can provide new messages.
Illustration 45 g03501777
Location of films
(1) Engine Oil film
(2) Diesel Fuel Requirements filmEngine Oil (1)
This film is located next to the engine oil filler tube on the right side of the machine.
Illustration 46 g02448560Cat® DEO-ULS oils and oils that satisfy the "API CJ-4"and/or "ACEA E9" requirements are required for engines that are equipped with a diesel particulate filter.Diesel Fuel Requirements (2)
This film is located next to the fuel cap on the right side of the machine.
Illustration 47 g03619316Use Ultralow Sulfur Diesel (ULSD) fuel.The Environmental Protection Agency (EPA) defines Ultra-Low Sulfur Diesel (ULSD - S15) as “a diesel fuel with a sulfur content not to exceed 15 parts per million (ppm(mg/kg)) or 0.0015 percent by weight”. Engines are equipped with exhaust after-treatment systems are designed to run on ULSD only. Use of LSD or fuels higher than 15 ppm (mg/kg) sulfur in these engines will reduce engine efficiency and engine durability. Damage to the emissions control systems and/or shortened service interval will occur. Failures that result form the use of fuels are not Caterpillar factory defects. Therefore the cost of repairs would not be

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101602-2492  
9 400 614 776 
220203651B 
INJECTION-PUMP ASSEMBLY
W06D
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