Information injection-pump assembly
BOSCH
F 019 Z10 328
f019z10328
ZEXEL
101481-0200
1014810200
ISUZU
8971033190
8971033190
Rating:
Service parts 101481-0200 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97042-322-1
12.
Open Pre:MPa(Kqf/cm2)
13.2(135)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 328
f019z10328
ZEXEL
101481-0200
1014810200
ISUZU
8971033190
8971033190
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.8
2.75
2.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive 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
11.7
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
73
71.4
74.6
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
400
400
400
Average injection quantity
mm3/st.
13
11.7
14.3
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(11.7)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
73
72
74
Basic
*
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1375
1375
1375
Average injection quantity
mm3/st.
75.5
71.5
79.5
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.35
)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
59
55
63
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
93
93
109
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
950
950
950
Rack position
R1-0.7
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
950
950
950
Rack position
R1(11.7)
Boost pressure
kPa
49.3
49.3
49.3
Boost pressure
mmHg
370
370
370
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
2.5
2
3
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)Boost compensator stroke: BCL
----------
T1=J21 BCL=0.7+-0.1mm
----------
----------
T1=J21 BCL=0.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7.5deg+-5deg b=33deg+-3deg
----------
----------
a=7.5deg+-5deg b=33deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=45deg+-5deg b=29deg+-5deg
----------
----------
a=45deg+-5deg b=29deg+-5deg
0000001501 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Cover
1. Aneroid compensator unit adjustment
(1)Select the push rod 2 to obtain L2.
(2)Screw in (A) to obtain L1.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
(3)As there is hysterisis, measure when the absolute pressure drops.
(4)Hysterisis must not exceed rack position = h1.
----------
N1=950r/min L1=(1.5)mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(11.7)mm Rb=R1-0.25mm Pa=74.6+-2.7kPa(560+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=73+-1cm3/1000st Q2=(66.5)+-2cm3/1000st
----------
N1=950r/min L1=(1.5)mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(11.7)mm Rb=R1-0.25mm Pa=74.6+-2.7kPa(560+-20mmHg) Pb=61.6+-0.7kPa(462+-5mmHg) Q1=73+-1cm3/1000st Q2=(66.5)+-2cm3/1000st
0000001601 ACS
(A) Aneroid compensator
(B) Set screw
(C) Boost pressure inlet
(D) Rack positioning screw
(E): Aneroid compensator main body
(F) Boost compensator spring
(G): Aneroid compensator spring
(H): Adjusting notch
(I) Push rod
1. Instructions for adjusting the boost compensator with the aneroid compensator
(1)Select a pushrod to obtain L1 at full boost.
(2)Remove the aneroid compensator main body.
(3)Adjust the booster compensator stroke by turning the screw at (D.
(4)Adjust the beginning of boost compensator operation by turning the notch at (H).
(5)Install the aneroid compensator at full boost state.
(6)Turn (B)'s set screw so that the distance between the snapring and the body is L2.
(7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(100deg)
----------
aa=10deg
----------
a=(100deg)
Information:
Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action. Please follow the Special Instruction, M0110497, "Removal and Installation Procedure for DEF Heated Lines on Certain Machine Engines" for proper Disassembly and Assembly of the DEF heated lines to avoid failures. If a failure or DEF leak is noted even after following the special instructions, please use Service Magazine, M0103829, "Diesel Exhaust Fluid (DEF) Heated Lines May Be Damage on Certain Cat® Machines" for a temporary line repair. If additional help is needed, please go to the Parts Tech tab and enter a Product Health ticket in PSCRM.The new hose assemblies are listed in Table 1.
Table 1
Item Qty New Part Number Part Name
1 1 457-9011 Return Hose Assembly
2 1 457-9013 Return Hose Assembly
3 1 457-9026 Return Hose Assembly
4 1 457-9027 Return Hose Assembly
5 1 462-4206 Hose As
6 1 462-4210 Hose As
7 1 462-4211 Hose As
8 1 462-4219 Hose As
9 1 462-4220 Hose As
10 1 462-4221 Hose As
11 1 462-4223 Hose As
12 1 462-4224 Hose As
13 1 475-3231 Hose As
14 1 475-3232 Hose As
15 1 475-3233 Hose As
16 1 475-3234 Hose As
17 1 475-9989 Hose As
18 1 478-9071 Hose As
19 1 478-9072 Hose As
20 1 478-9074 Hose As
21 1 478-9075 Hose As
22 1 478-9077 Hose As
23 1 478-9078 Hose As
24 1 478-9079 Hose As
25 1 478-9081 Hose As
26 1 478-9082 Hose As
27 1 478-9083 Hose As
28 1 478-9085 Hose As
29 1 478-9086 Hose As
30 1 497-9305 Hose As
31 1 497-9306 Hose As
32 1 497-9307 Hose As
33 1 497-9308 Hose As
34 1 500-6215 Return Hose Assembly
35 1 500-6216 Return Hose Assembly
36 1 500-6217 Hose As
37 1 500-6218 Hose As
38 1 500-6219 Hose As
39 1 500-6220 Hose As
40 1 500-6221 Hose As
41 1 500-6222 Hose As
42 1 500-6223 Hose As
43 1 500-6224 Hose As
44 1 510-5191 Return Hose Assembly
45 1 510-5192 Hose As
46 1 510-5193 Hose As
47 1 510-5194 Hose As
48 1 552-3292 Hose As
49 1 552-3293 Hose As
50 1 552-3294 Hose As
51 1 552-3295 Hose As
52 1 579-9200 Hose As
53 1 579-9201 Hose As
54 1 579-9202 Hose As
55 1 579-9203 Hose As
Caterpillar is aware of this problem and is recommending the following interim corrective action. Please follow the Special Instruction, M0110497, "Removal and Installation Procedure for DEF Heated Lines on Certain Machine Engines" for proper Disassembly and Assembly of the DEF heated lines to avoid failures. If a failure or DEF leak is noted even after following the special instructions, please use Service Magazine, M0103829, "Diesel Exhaust Fluid (DEF) Heated Lines May Be Damage on Certain Cat® Machines" for a temporary line repair. If additional help is needed, please go to the Parts Tech tab and enter a Product Health ticket in PSCRM.The new hose assemblies are listed in Table 1.
Table 1
Item Qty New Part Number Part Name
1 1 457-9011 Return Hose Assembly
2 1 457-9013 Return Hose Assembly
3 1 457-9026 Return Hose Assembly
4 1 457-9027 Return Hose Assembly
5 1 462-4206 Hose As
6 1 462-4210 Hose As
7 1 462-4211 Hose As
8 1 462-4219 Hose As
9 1 462-4220 Hose As
10 1 462-4221 Hose As
11 1 462-4223 Hose As
12 1 462-4224 Hose As
13 1 475-3231 Hose As
14 1 475-3232 Hose As
15 1 475-3233 Hose As
16 1 475-3234 Hose As
17 1 475-9989 Hose As
18 1 478-9071 Hose As
19 1 478-9072 Hose As
20 1 478-9074 Hose As
21 1 478-9075 Hose As
22 1 478-9077 Hose As
23 1 478-9078 Hose As
24 1 478-9079 Hose As
25 1 478-9081 Hose As
26 1 478-9082 Hose As
27 1 478-9083 Hose As
28 1 478-9085 Hose As
29 1 478-9086 Hose As
30 1 497-9305 Hose As
31 1 497-9306 Hose As
32 1 497-9307 Hose As
33 1 497-9308 Hose As
34 1 500-6215 Return Hose Assembly
35 1 500-6216 Return Hose Assembly
36 1 500-6217 Hose As
37 1 500-6218 Hose As
38 1 500-6219 Hose As
39 1 500-6220 Hose As
40 1 500-6221 Hose As
41 1 500-6222 Hose As
42 1 500-6223 Hose As
43 1 500-6224 Hose As
44 1 510-5191 Return Hose Assembly
45 1 510-5192 Hose As
46 1 510-5193 Hose As
47 1 510-5194 Hose As
48 1 552-3292 Hose As
49 1 552-3293 Hose As
50 1 552-3294 Hose As
51 1 552-3295 Hose As
52 1 579-9200 Hose As
53 1 579-9201 Hose As
54 1 579-9202 Hose As
55 1 579-9203 Hose As