101601-9792 ZEXEL F 019 Z10 822 BOSCH INJECTION-PUMP ASSEMBLY f019z10822 1016019792

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 822 f019z10822

ZEXEL 101601-9792 1016019792

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Buy INJECTION-PUMP ASSEMBLY 101601-9792 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-9792 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9980

3. GOVERNOR 105931-3731

4. SUPPLY PUMP 105210-4850

5. AUTOM. ADVANCE MECHANIS 105643-0280

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101402-3881 as _

101402-3882

101601-9792 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 822 f019z10822

ZEXEL 101601-9792 1016019792

Zexel num

Bosch num

Firm num

Name

101601-9792

F 019 Z10 822

INJECTION-PUMP ASSEMBLY
* 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 131424-5520

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.75+-0 .5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 46.7 45.5 47.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.7+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 7.6 6.5 8.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.75 )

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 46.7 45.7 47.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position (R1+0.4)

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 66.1 64.1 68.1

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 45.5 41.5 49.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.7 7.4 10

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.8

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
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=F53
----------

Speed control lever angle

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

----------
a=18.5deg+-5deg b=41deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1550r/min bb=6.7-0.5mm cc=275r/min dd=(8.3)mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(1deg)

Information:

*******Group 16*******
100% 100% 0% 0% 0% 0%
This is a 5.0-hour job for Group 16
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 17*******
100% 100% 0% 0% 0% 0%
This is a 7.0-hour job for Group 17
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 18*******
100% 100% 0% 0% 0% 0%
This is a 8.0-hour job for Group 18
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 19*******
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job for Group 19
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
EXAMPLE COPY OF OWNER NOTIFICATION
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING FUEL INJECTORS
MODELS INVOLVED - CERTAIN 3508C, 3512B, 3512C, 3516C, AND 3516E GENERATOR SETS, MARINE ENGINES, AND PETROLEUM ENGINES
Dear Cat Product Owner:
Certain fuel injectors need to be replaced on the products listed below. The existing fuel injectors can cause the cylinder to be over fueled and possibly lead to engine damage. You will not be charged for the service performed.
Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 19Mar2018 when scheduling this service.
We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 19Mar2018 Service Letter