101602-5091 ZEXEL F 019 Z10 979 BOSCH INJECTION-PUMP ASSEMBLY f019z10979 1016025091 220206390b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 979 f019z10979

ZEXEL 101602-5091 1016025091

HINO 220206390B 220206390b

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Buy INJECTION-PUMP ASSEMBLY 101602-5091 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-5091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6840

3. GOVERNOR 105411-2650

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1520

7. COUPLING PLATE 156639-8920

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8601

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.7(170)/21.6(220)

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE

15. NOZZLE SET 105019-2611

Include in #1:

101402-0631 as _

101602-5091 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 979 f019z10979

ZEXEL 101602-5091 1016025091

HINO 220206390B 220206390b

Zexel num

Bosch num

Firm num

Name

101602-5091

F 019 Z10 979

220206390B HINO

INJECTION-PUMP ASSEMBLY
J08C-TI K 14BN INJECTION PUMP ASSY PE

101602-5091

F 019 Z10 979

22100E0010 HINO

INJECTION-PUMP ASSEMBLY
J08C-TI A K 14BN INJECTION PUMP ASSY 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 10.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 155 153 157

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 8 7 9

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 11.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 150 150 160

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 9.5

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.8

Boost pressure kPa 22.7 16 29.4

Boost pressure mmHg 170 120 220

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=16 BCL=1.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(11deg)+-5deg b=(28deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Rack position bb, pump speed cc (seal at delivery) (3)Normal
----------
aa=25mm bb=2-0.5mm cc=0r/min
----------
a=19deg+-5deg b=(53deg)

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:

Features and Benefits
Reman short blocks expand the repair options available. When used with other
remanufactured products and reusable components from the core engine, short blocks help
lower dealer repair/rebuild cost and shorten turnaround time.
The 3500B short block is a fully assembled cylinder block with sequence valves, crankshaft,
cylinder pack groups, piston jets, camshaft bearings, and lifting eyes.
The short block does not include camshaft, cam access covers, or block side covers. The
short block may contain a remanufactured cylinder block, crankshaft, connecting rods, and
pistons. The cylinder liners, piston rings, camshaft bearings, and crankshaft bearings are
100% new components. The remanufactured components are remanufactured to factory
specifications using factory precision machine tools and proven processes.
Core Acceptance
Short blocks from 3500B diesel series machine and commercial engines that were built with
101-0829 Piston ? Rod Gp. are acceptable as core. Reference SELD0026 for the latest Short
Block Core Acceptance Criteria.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts
Information application describing all reman part/CAF and related information. Also refer to
other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes,
Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry,
CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to
properly manage core returns and monitor inspection performance. This information will be
available to all dealers worldwide after your CMIS 2 conversion date. In the meantime,
please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list
of parts in a Core Acceptability Family (CAF) and related part number detail.
For the latest updates of Reman Policies and Core Management (SELD0122), Core
Management Systems & Operations Procedures (SELD0040), and Shipping Instructions
(SELD0039), go to the Reman website and click on Procedures and Policies (listed under
Reman Program Information).
Please note that 3500B short block core will be shipped to Lafayette address:
Caterpillar Inc.
3701 State Road 26 East
Lafayette, Indiana, 47905
U.S.A.
See "SHIPPING INSTRUCTIONS" (SELD0039) for more information.
If you have any questions regarding core return processing, feel free to call Corinth toll free
at (800) 537-2928. For assistance with technical questions, call the Peoria Reman
Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail
address--Reman_Help.
James E. Reynolds
Dept: 3500 Reman Engines
Location: 88-B21L
Phone: 765-448-2295
Fax: 765-448-5897