Information injection-pump assembly
BOSCH
F 019 Z10 500
f019z10500
ZEXEL
101602-9951
1016029951
MITSUBISHI-HEAV
3436101031
3436101031
Rating:
Service parts 101602-9951 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 500
f019z10500
ZEXEL
101602-9951
1016029951
MITSUBISHI-HEAV
3436101031
3436101031
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
131424-5720
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
74.2
73.2
75.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
12
10.7
13.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
58
58
63
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)The torque control spring does not operate.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=15
----------
----------
K=15
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=14deg+-5deg b=29deg+-5deg
----------
----------
a=14deg+-5deg b=29deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Hold the boss against the stop side
----------
----------
a=26.5deg+-5deg b=53deg+-5deg c=(9deg)
----------
----------
a=26.5deg+-5deg b=53deg+-5deg c=(9deg)
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Refer to attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
2001-5000 hrs,
13-18 mo 100.0% 50.0% 0.0% 0.0% 0.0% 50.0%
5001-8000 hrs,
19-24 mo 100.0% 30.0% 0.0% 0.0% 0.0% 70.0%
This is a 4.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
2001-5000 hrs,
13-18 mo 100.0% 50.0% 0.0% 0.0% 0.0% 50.0%
5001-8000 hrs,
19-24 mo 100.0% 30.0% 0.0% 0.0% 0.0% 70.0%
This is a 4.0-hour job for Group 2
PARTS DISPOSITION
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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
For the following units listed remove (6) 207-5248 Injector Rocker Arms, and replace with (6) 278-1365 Injector Rocker Arms.
For proper ?Disassembly & Assembly? instructions of the injector rocker arms please refer to the following Publications in SIS Web. (SENR9832-06 Testing & Adjusting-Finding Top Dead Center Position for No. 1 Piston), (SENR9832-06 Testing & Adjusting-Electronic Unit Injector Adjusting & Setting), and (SENR9832-06 Testing & Adjusting-Engine Valve Lash Inspect/Adjust).
Note: It is important that while installing the 278-1365 Injector Rocker Arms, that the engine is in the proper position (Top Dead Center and 180 degrees out) so the Injector Rocker Arms are properly adjusted and set. It is also important that during the installation of the Injector Rocker Arms that the Exhaust Valve, and Intake Valve lash settings be inspected and if needed re-set to factory specifications.
Note: During the rework process please inspect the 6I-0901 Rocker Arm Shafts for any signs of misalignment of the stud mounting holes, wear, damage, fretting etc. If damage is found to the shaft or if fretting or damage is found with any of the through bolt/stud mounting holes, the shaft is to be replaced, and reported against this service letter as contingent damage.