101602-2830 ZEXEL 9 400 610 576 BOSCH INJECTION-PUMP ASSEMBLY 9400610576 1016022830


 

Information injection-pump assembly

BOSCH 9 400 610 576 9400610576
ZEXEL 101602-2830 1016022830
101602-2830 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101602-2830 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2830 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9940
3. GOVERNOR 105400-8510
4. SUPPLY PUMP 105220-5300
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156636-8820
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-5161
11. Nozzle and Holder 23600-2142A
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105041-5041
14. NOZZLE 105015-8241
15. NOZZLE SET

Include in #1:

101602-2830 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 576 9400610576
ZEXEL 101602-2830 1016022830


Zexel num
Bosch num
Firm num
Name
101602-2830 
101602-2831 
9 400 610 576 
   
INJECTION-PUMP ASSEMBLY
* K 14BE PE6A 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   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   3.45 3.42 3.48
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   10
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   47.9 45.9 49.9
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7.5+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   9 7.5 10.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   75 75 85
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101602-2830
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
----------
K=9
----------

Speed control lever angle

Test data 101602-2830
F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting (3)When pump speed set at aa (4)Set the pump speed at bb.
----------
aa=755r/min bb=900r/min
----------
a=5deg+-5deg b=18deg+-5deg c=1deg+-5deg

Stop lever angle

Test data 101602-2830
N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=7mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

Test data 101602-2830
(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:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Illustration 1 g06201989Certain Cat® Reman 3500 electronic fuel injectors may be marked with incorrect trim codes. Cat Reman 3500 electronic fuel injectors marked with trim code "2755" manufactured between 09 January 2017and 18 April 2017may be affected.The trim code is not correct for every injector. Refer to Illustration 1 for trim code identification. Serial numbers of suspect injectors range from (S/N: 1825569-1880788).Solution
Caterpillar is aware of this problem, but a permanent repair has not been identified. As an interim action, follow the below procedure:
All Reman 3500 electronic fuel injectors marked with trim code "2755" manufactured between 09 January 2017and 18 April 2017are suspect. Refer to Illustration 1.Caterpillar has created a tool which will help to identify injectors labeled with the incorrect trim code. Use the link below to download the file.https://cat.box.com/s/4fwh9nz0lwguh8vomifxj2rapqjc27e9
Enter the injector Serial Number in the spreadsheet downloaded. The spreadsheet will indicate whether the code is ok to use as is, or the spreadsheet will return the correct trim code.
Illustration 2 g06203882
If the trim code is incorrect, the injector must be relabeled. Use an engraving tool to cross out the original (incorrect) trim code (2755) and write the correct trim code on the injector tappet. Refer to Illustration 2.
Illustration 3 g06202000
Mark the box for each part that has been either reworked or verified to be correct, to identify that the parts are good to use. Refer to Illustration 3.
For individual injector replacements in engines, update the ECM with the correct trim code. Injectors must be marked with the correct trim code.Note: Do not return affected parts to Caterpillar. Use the procedure listed above to remark and use existing stock.Note: The issue has been resolved in the factory. Factory stock has been reworked and shipped. Parts in the distribution system are being sorted for return & rework.Note: Injector boxes have been marked with a large green dot to indicate that the injector has been sorted and marked correctly, or the trim code is correct.

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