Information injection-pump assembly
BOSCH
F 019 Z10 820
f019z10820
ZEXEL
101601-5790
1016015790
HINO
220007310A
220007310a

Rating:
Service parts 101601-5790 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236002360A
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 820
f019z10820
ZEXEL
101601-5790
1016015790
HINO
220007310A
220007310a
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.6
76
79.2
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
9+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
16.9
15.9
17.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.6
76.6
78.6
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
88.9
84.9
92.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
64.2
60.2
68.2
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.5
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
87.4
83.4
91.4
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4.5
4.2
4.8
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=F03
----------
----------
T1=F03
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=(40deg)+-5deg b=44deg+-5deg
----------
aa=57mm
----------
a=(40deg)+-5deg b=44deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg
0000001501 TAMPER PROOF

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=1450r/min Ra=(0.4)mm Rb=R1(11.5)+1.05mm Rc=R1(11.5)+1.05mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
----------
N1=1450r/min Ra=(0.4)mm Rb=R1(11.5)+1.05mm Rc=R1(11.5)+1.05mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Maintenance Recommendations
Caterpillar Inc. truck engines are certified by the United States Environmental Protection Agency (EPA) to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture.Efficiency of emission control and engine performance depends on adherence to proper operation and maintenance recommendations AND use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be made by your authorized Caterpillar dealer.Various chemical fuel additives claiming to reduce visible smoke are available commercially. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require that engines be certified without smoke depressants.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the owner that the use of such parts will not adversely affect emission levels.Regular maintenance intervals, along with special emphasis on the following items, are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the MaintenanceManagement Schedule and Maintenance Section of this manual for details. If the engine is operating under severe conditions, adjust the maintenance schedule accordingly. See your authorized Caterpillar dealer to help analyze your specific application, operating environment and maintenance schedule adjustments.The following is an explanation of maintenance for emission-related components. See the Maintenance Management Schedule for the specific interval for the following items. ELECTRONIC UNIT INJECTORS - Damaged fuel injectors will normally cause the engine to misfire, run rough and smoke. Test and replace if necessary as recommended in the Maintenance Management Schedule. Fuel injectors can be tested by an authorized Caterpillar truck engine dealer. TURBOCHARGER - Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Management Schedule.Owner is encouraged to keep adequate maintenance records, but the absence of such, in and of itself, will not invalidate the warranty.The vehicle owner may perform routine maintenance, repairs and other non warranty work or have it done at any repair facility. Such non warranty work need not be performed at a designated warranty station in order for the warranty to remain in forceCustomer Assistance
Caterpillar Inc. aims to ensure that the Emission Control Systems warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, call or write:Caterpillar Inc.
Manager, Truck Engine Business
Peoria, Illinois 61629
Ph. (309) 578-6288
Authorized dealers are recommended for major maintenance and repair work as they are staffed with trained personnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others who desire to perform their own work should purchase a Service Manual and obtain current service information from their Caterpillar dealer.For information regarding an
Caterpillar Inc. truck engines are certified by the United States Environmental Protection Agency (EPA) to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture.Efficiency of emission control and engine performance depends on adherence to proper operation and maintenance recommendations AND use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be made by your authorized Caterpillar dealer.Various chemical fuel additives claiming to reduce visible smoke are available commercially. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require that engines be certified without smoke depressants.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the owner that the use of such parts will not adversely affect emission levels.Regular maintenance intervals, along with special emphasis on the following items, are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the MaintenanceManagement Schedule and Maintenance Section of this manual for details. If the engine is operating under severe conditions, adjust the maintenance schedule accordingly. See your authorized Caterpillar dealer to help analyze your specific application, operating environment and maintenance schedule adjustments.The following is an explanation of maintenance for emission-related components. See the Maintenance Management Schedule for the specific interval for the following items. ELECTRONIC UNIT INJECTORS - Damaged fuel injectors will normally cause the engine to misfire, run rough and smoke. Test and replace if necessary as recommended in the Maintenance Management Schedule. Fuel injectors can be tested by an authorized Caterpillar truck engine dealer. TURBOCHARGER - Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Management Schedule.Owner is encouraged to keep adequate maintenance records, but the absence of such, in and of itself, will not invalidate the warranty.The vehicle owner may perform routine maintenance, repairs and other non warranty work or have it done at any repair facility. Such non warranty work need not be performed at a designated warranty station in order for the warranty to remain in forceCustomer Assistance
Caterpillar Inc. aims to ensure that the Emission Control Systems warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, call or write:Caterpillar Inc.
Manager, Truck Engine Business
Peoria, Illinois 61629
Ph. (309) 578-6288
Authorized dealers are recommended for major maintenance and repair work as they are staffed with trained personnel, proper tools and are aware of the latest maintenance methods and procedures. Owners and others who desire to perform their own work should purchase a Service Manual and obtain current service information from their Caterpillar dealer.For information regarding an