Information injection-pump assembly
BOSCH
F 019 Z10 315
f019z10315
ZEXEL
101401-4371
1014014371
ISUZU
8970655231
8970655231

Rating:
Service parts 101401-4371 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-016-0
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 315
f019z10315
ZEXEL
101401-4371
1014014371
ISUZU
8970655231
8970655231
Zexel num
Bosch num
Firm num
Name
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
105780-8140
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.1
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
61
59.4
62.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
15.5
14.2
16.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.1)
Pump speed
r/min
960
960
960
Average injection quantity
mm3/st.
61
60
62
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
79.5
75.5
83.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
76
76
108
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1375--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3.3
2.8
3.8
Timer adjustment_04
Pump speed
r/min
1600--
Advance angle
deg.
5
4.5
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.
----------
T1=H72
----------
----------
T1=H72
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=43deg+-5deg b=(42deg)+-3deg
----------
----------
a=43deg+-5deg b=(42deg)+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD

(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm
Timing setting

(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)Pump bracket check hole position.
(5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1.
(6)B.T.D.C.: aa
----------
aa=10deg
----------
a=(60deg) b=(85deg)
----------
aa=10deg
----------
a=(60deg) b=(85deg)
Information:
Lubrication Specifications
Crankcase Lubricating Oils
Use oils which meet Engine Service Classification CD (MIL-L-2104D) or CD/TO-2. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines.Consult the "EMA Lubricating Oils Data Book," Form SEBU5939, for a listing of CD oil brands.The proper SAE grade of oil to select is determined by the ambient temperature at which the engine is started and the maximum ambient temperature in which the engine will be operating. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly.Lubricating Grease
Use Multipurpose-type Grease (MPGM) which contains 3-5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 0 or No. 1 Grade for extremely low temperatures.Recommended Lubricant Viscosities
Air Starting Motor Oiler: Use SAE 10W in all temperatures.Flywheel Clutch Bearing Reservoir: Use SAE 30 in all temperatures. Fuel Specifications
No. 2 fuel oil and No. 2D diesel fuel are recommended for use in Caterpillar Diesel Engines. In extreme cold temperatures use No. 1 fuel oil or No. 1D diesel fuel.In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed, thus eliminating all sediment and residue.There is considerable variation in the composition of fuels distributed under the No. 2 grade classifications. For desirable engine service it is most important to give special attention to cetane no., water and sediment, pour point, cloud point and sulphur content. USE THE LOWEST PRICE DISTILLATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS.Water and Sediment 0.1% sedimentCetane No. (PC Engine) 35 minimum(DI Engine) 40 minimumPour Point 10°F (6°C) below ambient temperatureCloud Point No higher than ambient temperatureSulphur Content* Adjust oil change periodGravity 32-40 A.P.I. at 60°F (15.6°C)*See the topic SULPHUR CONTENT. Cetane No: This is an indication of a fuel's ignition quality and should not be less than 35 for the PC engine and 40 for the DI engine. For high altitude operation or cold weather starting, a higher cetane number is required. Water and Sediment: A good clean fuel will contain no more than 0.1% sediment and water. Dirty fuels lead to early filter plugging and in addition can result in the formation of gums and resins reducing filter and engine life. Pour Point: The pour point of the fuel has no effect on engine performance, as long as the fuel is fluid enough to flow from the fuel tank to the engine. The pour point of the fuel should be at least 10°F (6°C) below the lowest atmospheric temperature at which the engine must start and operate. In extremely cold temperatures it may be necessary to use No. 1 fuel oil or No. 1D diesel fuel. Cloud Point: Cloud point is the temperature at which wax crystals become visible and is generally above the pour point of
Crankcase Lubricating Oils
Use oils which meet Engine Service Classification CD (MIL-L-2104D) or CD/TO-2. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines.Consult the "EMA Lubricating Oils Data Book," Form SEBU5939, for a listing of CD oil brands.The proper SAE grade of oil to select is determined by the ambient temperature at which the engine is started and the maximum ambient temperature in which the engine will be operating. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly.Lubricating Grease
Use Multipurpose-type Grease (MPGM) which contains 3-5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 0 or No. 1 Grade for extremely low temperatures.Recommended Lubricant Viscosities
Air Starting Motor Oiler: Use SAE 10W in all temperatures.Flywheel Clutch Bearing Reservoir: Use SAE 30 in all temperatures. Fuel Specifications
No. 2 fuel oil and No. 2D diesel fuel are recommended for use in Caterpillar Diesel Engines. In extreme cold temperatures use No. 1 fuel oil or No. 1D diesel fuel.In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed, thus eliminating all sediment and residue.There is considerable variation in the composition of fuels distributed under the No. 2 grade classifications. For desirable engine service it is most important to give special attention to cetane no., water and sediment, pour point, cloud point and sulphur content. USE THE LOWEST PRICE DISTILLATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS.Water and Sediment 0.1% sedimentCetane No. (PC Engine) 35 minimum(DI Engine) 40 minimumPour Point 10°F (6°C) below ambient temperatureCloud Point No higher than ambient temperatureSulphur Content* Adjust oil change periodGravity 32-40 A.P.I. at 60°F (15.6°C)*See the topic SULPHUR CONTENT. Cetane No: This is an indication of a fuel's ignition quality and should not be less than 35 for the PC engine and 40 for the DI engine. For high altitude operation or cold weather starting, a higher cetane number is required. Water and Sediment: A good clean fuel will contain no more than 0.1% sediment and water. Dirty fuels lead to early filter plugging and in addition can result in the formation of gums and resins reducing filter and engine life. Pour Point: The pour point of the fuel has no effect on engine performance, as long as the fuel is fluid enough to flow from the fuel tank to the engine. The pour point of the fuel should be at least 10°F (6°C) below the lowest atmospheric temperature at which the engine must start and operate. In extremely cold temperatures it may be necessary to use No. 1 fuel oil or No. 1D diesel fuel. Cloud Point: Cloud point is the temperature at which wax crystals become visible and is generally above the pour point of