Information injection-pump assembly
BOSCH
9 400 614 776
9400614776
ZEXEL
101602-2492
1016022492
HINO
220203651B
220203651b

Rating:
Service parts 101602-2492 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1580
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101602-2492
as INJECTION-PUMP ASSEMBLY
Include in #2:
104234-2004
as _
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
W06D K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
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.
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

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
----------
----------
K=11
----------
Speed control lever angle

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
----------
aa=900r/min bb=750r/min
----------
a=(2deg)+-5deg b=(15deg)+-5deg c=(5deg)+-5deg
Stop lever angle

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)
----------
aa=2.5+-0.5mm bb=6.9mm cc=0r/min
----------
a=27deg+-5deg b=53deg+-5deg c=(6deg)
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)
----------
----------
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
Have questions with 101602-2492?
Group cross 101602-2492 ZEXEL
Hino
Hino
Hino
Hino
101602-2492
9 400 614 776
220203651B
INJECTION-PUMP ASSEMBLY
W06D
W06D