101602-5071 ZEXEL 9 400 613 104 BOSCH INJECTION-PUMP ASSEMBLY 9400613104 1016025071 220206071a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 104 9400613104

ZEXEL 101602-5071 1016025071

HINO 220206071A 220206071a

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Buy INJECTION-PUMP ASSEMBLY 101602-5071 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-5071 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6710

3. GOVERNOR 105411-2620

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105622-1520

7. COUPLING PLATE 156639-8920

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5380

11. Nozzle and Holder 23600-3600A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105030-2010

14. NOZZLE 105025-3190

15. NOZZLE SET

Include in #1:

101602-5071 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-1064 as _

Cross reference number

BOSCH 9 400 613 104 9400613104

ZEXEL 101602-5071 1016025071

HINO 220206071A 220206071a

Zexel num

Bosch num

Firm num

Name

101602-5071

9 400 613 104

220206071A HINO

INJECTION-PUMP ASSEMBLY
J08C-TI K 14BF INJECTION PUMP ASSY PE6AD PE

101602-5071

9 400 613 104

S220206071 HINO

INJECTION-PUMP ASSEMBLY
J08C-TI A K 14BF INJECTION PUMP ASSY PE6AD PE

101602-5071

9 400 613 104

S220206071A HINO

INJECTION-PUMP ASSEMBLY
J08C-TI B 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 131425-0620

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.8 3.77 3.83

Beginning of injection position
Governor 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 9.1

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 117 115 119

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 107.5 104.5 110.5

Fixing the rack *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_03

Adjusting point D

Rack position 6.5+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-0.8

Boost pressure kPa 3.3 3.3 8.6

Boost pressure mmHg 25 25 65

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(9.5)

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

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)Boost compensator excessive fuel lever at operation: L1 (4)Boost compensator stroke: BCL (5)Set idle sub-spring
----------
K=11 L1=10.6+-0.1mm BCL=0.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)When pump speed set at bb (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=1deg+-5deg b=21deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal stop (2)Rack position aa or less, pump speed bb
----------
aa=6mm bb=0r/min
----------
a=19deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (2)Stopper bolt setting (3)Use the hole at R = bb (4)Drive side (5)At boost pressure = cc
----------
aa=10.6+-0.1mm bb=30mm cc=0kPa(0mmHg)
----------
a=(11deg) b=(4deg)

Timing setting

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

----------
a=(20deg)

Information:

face="Courier New" size=-1>0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 2
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 3*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 3
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 4*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 4
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 5*******
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.0-hour job for Group 5
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Engine Injector Change:
First identify which level of injector you currently have in your engine and establish which is the latest injector to replace it.
To remove and replace the injectors use the following Disassembly and Assembly Instructions.
C6.6 Caterpillar Industrial Engines: Install and Remove procedure RENR9722
C6.6 Caterpillar Built Machine: Install and Remove procedure KENR6081
Engine Reflash:
To update the flash file follow the procedure below. Refer to TMI or SISWeb for the latest flash file.
Tools Required:
PC or laptop with CAT ET installed and licensed (Version 2007A minimum) Communication Adaptor with diagnostic connector.
Flash File procedure:
Process:
1. Download the correct flash file from TMI or SISWeb.
2. Save the correct flash file to your local hard drive.
3. Connect to the ECM using Service Tool (CAT ET).
4. Make sure the ECM is powered up (Check that Red light on Comm. Adaptor is illuminated).
5. Go to "Winflash" or "Flash Memory".
6. CAT ET re-connect to the ECM.
7. Using the browse function in the top right hand corner, select the new flash file previously saved to hard drive.
8. Select "Begin Flash" (bottom right hand corner).
9. Once Flashing is complete select "CAT ET".
10. The Personality Module Mismatch should appear, select the ok button.
11. The factory password screen should now appear.
12. Use https://fps.cat.com to obtain factory passwords.
13. Enter Factory Passwords.
14. CAT ET High Level Configuration screen should be displayed.
15. Re-flash complete.