Information injection-pump assembly
BOSCH
9 400 610 562
9400610562
ZEXEL
101501-2031
1015012031
HINO
220009040A
220009040a

Rating:
Service parts 101501-2031 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2663C
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
14.
NOZZLE
Include in #1:
101501-2031
as INJECTION-PUMP ASSEMBLY
Include in #2:
104761-4090
as _
Cross reference number
BOSCH
9 400 610 562
9400610562
ZEXEL
101501-2031
1015012031
HINO
220009040A
220009040a
Zexel num
Bosch num
Firm num
Name
9 400 610 562
220009040A HINO
INJECTION-PUMP ASSEMBLY
J07C * K 14BL PE 5MD PE
J07C * K 14BL PE 5MD PE
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131425-0320
Overflow valve opening pressure
kPa
108
88
128
Overflow valve opening pressure
kgf/cm2
1.1
0.9
1.3
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-2-4-5-
3
Pre-stroke
mm
4
3.97
4.03
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 72 71.75 72.25
Cyl.1-2 deg. 72 71.75 72.25
Difference between angles 2
Cal 1-4 deg. 144 143.75 144.25
Cal 1-4 deg. 144 143.75 144.25
Difference between angles 3
Cal 1-5 deg. 216 215.75 216.25
Cal 1-5 deg. 216 215.75 216.25
Difference between angles 4
Cal 1-3 deg. 288 287.75 288.25
Cal 1-3 deg. 288 287.75 288.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.2
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
100
98.4
101.6
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
415
415
415
Each cylinder's injection qty
mm3/st.
12
11
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.2)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
100
99
101
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
103
99
107
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.45
Pump speed
r/min
1160
1160
1160
Average injection quantity
mm3/st.
105.5
101.5
109.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-0.75
Pump speed
r/min
580
580
580
Average injection quantity
mm3/st.
84
80
88
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1-0.9
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
77
71
83
Fixing the lever
*
Injection quantity adjustment_08
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
170
170
180
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Load
1/5
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.3
Load
1/5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1
0.7
1.3
Load
5/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1190++
Advance angle
deg.
1
0.7
1.3
Load
2/5
Timer adjustment_05
Pump speed
r/min
(1300-50
)
Advance angle
deg.
1
0.7
1.3
Load
5/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_06
Pump speed
r/min
1450-50
Advance angle
deg.
5.5
5.2
5.8
Load
5/5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=K64
----------
----------
T1=K64
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=8deg+-5deg b=38deg+-3deg
----------
aa=46mm
----------
a=8deg+-5deg b=38deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
SEPTEMBER 2009
INFORMATION RELEASE MEMO
Reman
PELJ1080 ?2009 Caterpillar
CAT REMAN ANNOUNCES THE INTRODUCTION OF AN UPGRADE TO NEW INJECTOR KIT FOR CERTAIN HIGH DISPLACEMENT 3500 ENGINES IN MINING APPLICATIONS
Announcement
Some mining customers have expressed a preference to use new fuel injectors during an engine rebuild as part of a bill of materials designed to produce a "zero" hour rebuilt engine standard. To provide an economical option to those customers, Cat Reman announces the introduction of an Upgrade to New (UTN) fuel injector kit option for certain 3500 engines in mining applications. This option will meet the customer need while enabling Cat Reman to capture the cores of those customers using new injectors.
These fuel injector kits will provide dealers and customers with an additional fuel injector replacement and repair option and come complete with four new fuel injectors and corresponding hold down bolts. Refer to the following table for part number details.
甀
Availability and Ordering
To support availability of these UTN kits for planned rebuilds, we ask dealers to place Future Dated Orders (FDOs) whenever possible.
Core Acceptance
Core Acceptance Criteria for CatP?PFuel Injectors is simple, visual, and requires no special tools. Consult the Unit Injectors ? Electronic Core Acceptance Criteria SELD0226 for complete details. The purchase of an UTN Kit establishes core entitlements at the consist part level quantity. For example, purchase of a kit of four UTN Injectors establishes four individual core injector entitlements.
Warranty
Please consult the appropriate CatP Pparts warranty statement for your area.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for your assigned Core Help Line Contact Information; the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as Policy and Core Management SELD0122 -10, "Core Management Systems and Operations Procedures SELD0040-14, "Reman Core Return Packaging Instructions And Guidelines SELD0300-00 and "Shipping Instructions" SELD0039-14.
If you have any questions regarding Reman Core Management or Core Management Information Systems (CMIS2), feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928. Outside the US please refer to the Core section of the Reman website for appropriate contact information for your region.
For assistance with technical questions, call the Peoria Reman Technical Help Line toll free at (888) 88-REMAN (outside the US call non-toll free +1-309-494-4342), or use our E-mail address--Reman_Help.