101602-2892 ZEXEL 9 400 612 069 BOSCH INJECTION-PUMP ASSEMBLY 9400612069 1016022892 220205272a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 069 9400612069

ZEXEL 101602-2892 1016022892

HINO 220205272A 220205272a

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Buy INJECTION-PUMP ASSEMBLY 101602-2892 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2892 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5640

3. GOVERNOR 105401-1032

4. SUPPLY PUMP 105210-5560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1280

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4100

11. Nozzle and Holder 23600-2710A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101602-2892 as INJECTION-PUMP ASSEMBLY

101603-8620 as _

Cross reference number

BOSCH 9 400 612 069 9400612069

ZEXEL 101602-2892 1016022892

HINO 220205272A 220205272a

Zexel num

Bosch num

Firm num

Name

101602-2892

9 400 612 069

220205272A HINO

INJECTION-PUMP ASSEMBLY
H07C-TD K 14BF INJECTION PUMP ASSY PE6AD 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 4.8 4.77 4.83

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 9.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 92.5 91 94

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_02

Adjusting point -

Rack position 6.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-0.6

Boost pressure kPa 20 20 22

Boost pressure mmHg 150 150 165

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(9.9)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

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)Boost compensator stroke: BCL (5)Set idle sub-spring
----------
K=6 BCL=0.6+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Stopper bolt setting (3)Stopper bolt setting (4)When pump speed set at bb
----------
aa=900r/min bb=750r/min
----------
a=0deg+-5deg b=19deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

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

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

Information:

Illustration 11 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
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 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 12 g06238625
Location of oil and fuel films
(1) Oil film
(2) Fuel filmEngine Oil (1)
This film is located in front of the engine oil filler tube and next to the fuel tank breather, on the right side of the machine.
Illustration 13 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 film next to the fuel filler and fuel tank inspection cover on the right side of the machine.
Illustration 14 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 covered by a Caterpillar warranty.In Europe, ultra low sulfur diesel fuel will have a maximum of 0.0010 percent (10 ppm (mg/kg)) sulfur and is typically referred to as “sulfur-free”. This sulfur level is defined in European Standard "EN 590:2004".Operational Requirements
Ensure that the following operational requirements are applied when machines are fitted with a wall flow diesel particulate filter.Fuel
Sulfur levels must not exceed 15 ppm
Do not use fuel additives, biofuels, or alternative diesel fuels not authorized by CaterpillarOil
Use manufacturer recommended engine oilMachine Operation
Avoid excessive or unnecessary idling and low load operation. High load, high temperature is recommended for machines equipped with flow through diesel particulate filtersLubricant Viscosities - Fluid Recommendations
Engine Oil
Cat® oils have been developed and tested to provide the full performance and life that has been designed and built