101601-5760 ZEXEL F 019 Z10 818 BOSCH INJECTION-PUMP ASSEMBLY f019z10818 1016015760 220007150a


 

Information injection-pump assembly

BOSCH F 019 Z10 818 f019z10818
ZEXEL 101601-5760 1016015760
HINO 220007150A 220007150a
101601-5760 INJECTION-PUMP ASSEMBLY
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Service parts 101601-5760 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9931
3. GOVERNOR 105921-4750
4. SUPPLY PUMP 105220-5140
5. AUTOM. ADVANCE MECHANIS 105676-0670
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-4292
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105041-5041
14. NOZZLE 105025-0490
15. NOZZLE SET

Include in #1:

101601-5760 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 818 f019z10818
ZEXEL 101601-5760 1016015760
HINO 220007150A 220007150a


Zexel num
Bosch num
Firm num
Name
101601-5760 
101601-5761 
F 019 Z10 818 
220007150A  HINO
INJECTION-PUMP ASSEMBLY
W06E A * K

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   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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.1 3.07 3.13
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   -
Rack position   9.2
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   52.4 50.4 54.4
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   H
Rack position   8+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   6.8 5.3 8.3
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(9.2)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   52.4 51.4 53.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.35
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   48.8 44.8 52.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.35
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   36.5 32.5 40.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.1
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   53.1 49.1 57.1
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   R1+0.2
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   29.2 25.2 33.2
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99 99 109
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1000+50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1500
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5760
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=C09
----------

Speed control lever angle

Test data 101601-5760
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=31deg+-3deg b=34deg+-5deg

Stop lever angle

Test data 101601-5760
N:Pump normal S:Stop the pump. (1)Engine normal (2)Stopper bolt setting (3)(Apply red paint after setting.)
----------

----------
a=40deg+-5deg b=40deg+-5deg c=35deg+-2deg

0000001501 TAMPER PROOF

Test data 101601-5760
1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1500r/min Ra=(0.4)mm Rb=R1(9.2)-0.05mm Rc=R1(9.2)-0.05mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

Test data 101601-5760
(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:

Lubricant Information
Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. SPC is a Caterpillar designation for special synthetic oils, that do not contain viscosity improvers. The MIL specifications are U.S.A. Military Specifications. The definitions other than Caterpillar's will be of assistance in purchasing lubricants. The recommended oil viscosities can be found in the"Lubricant Viscosities" chart in this publication.The grease is classified by the National Lubricating Grease Institute (NLGI) based on the ASTM D217-68 Worked Penetration characteristics which are given a defined consistency number.Engine Lubricant Specification
Caterpillar has an oil formulation to provide maximum performance and life in your truck engine.Engine Oil (EO)
Cat Engine Oil (EO) is a lubricant that meets the performance requirements of today's newer truck engines as well as meeting the needs of earlier built truck engines. This oil has sufficient TBN and sulfated ash level to be effective in operation.* Cat Engine Oil (EO)This lubricating oil also meets the industry standards for both diesel and gasoline engine requirements.Cat Engine Oil is Caterpillar's recommendation for an engine oil specifically intended for use in mixed fleets. This oil is only for the convenience of having the same oil for gasoline and diesel engines.Alternate Oils
Failure to follow these recommendations for CE performance oils can cause shortened engine life due to carbon deposits or excessive wear.
If an oil other than Cat oil is to be used, the following oil specifications provide selection guidelines.If circumstances require the use of an oil other than the Cat Engine Oil, the following oil specifications can be used; API specification CE, CE/SF or CE/SG.Oil with these specifications may require shortened oil change periods as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The Caterpillar 20 times rule for TBN versus fuel sulfur is a general requirement, but it can be modified by used oil analysis. The effectiveness of an oil formulation will depend on the additive package. A balanced additive package oil of a lower TBN can be as effective in fuel sulfur neutralization and overall performance as some oils with higher TBN values which have additives just for increased TBN. The used oil analysis can show these results.Consult the EMA Lubricating Oils Data Book, form SEBU6310 for a listing of oil brands meeting the CE requirements.For more information on oil and fuel sulfur content, refer to "Oil and Your Engine," form SEBD0640.Always consult with your Caterpillar dealer for the latest lubrication recommendations.Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.Cat Lubricating Grease
Caterpillar has greases for all applications.Cat Multipurpose Lithium Grease (MPGL) (non-extreme pressure)This NLGI No. 2 grade is recommended for light duty automotive type

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