Information injection-pump assembly
BOSCH
F 019 Z10 598
f019z10598
ZEXEL
101603-7453
1016037453

Rating:
Service parts 101603-7453 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-266-4
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Include in #1:
101603-7453
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-6772
as _
Cross reference number
BOSCH
F 019 Z10 598
f019z10598
ZEXEL
101603-7453
1016037453
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
-
Rack position
13.3
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97
100.2
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
275
275
275
Average injection quantity
mm3/st.
8
6.7
9.3
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(13.3)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97.6
99.6
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
98.6
95.4
101.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
55)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
78.6
75.4
81.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.35
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54
50.8
57.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
93
93
125
Fixing the lever
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R2-1.35
Boost pressure
kPa
3.3
3.3
6
Boost pressure
mmHg
25
25
45
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R2(R1-0.
55)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
(1170)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
1.5
1
2
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
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.
(3)Boost compensator stroke: BCL
----------
T1=F36 BCL=1.35+-0.1mm
----------
----------
T1=F36 BCL=1.35+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=48mm
----------
a=43deg+-5deg b=(37deg)+-3deg
----------
aa=48mm
----------
a=43deg+-5deg b=(37deg)+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR

V1:Supply voltage
V2f:Full side output voltage
V2i:Idle side output voltage
(A) Black
(B) Yellow
(C) Red
(D) Trimmer
(E): Shaft
(F) Nut
(G) Load lever
1. Load sensor adjustment
(1)Connect as shown in the above diagram and apply supply voltage V1.
(2)Hold the load lever (G) against the full side.
(3)Turn the shaft so that the voltage between (A) and (B) is V2.
(4)Hold the load lever (G) against the idle side.
(5)Adjust (D) so that the voltage between (A) and (B) is V2i.
(6)Repeat the above adjustments.
(7)Tighten the nut (F) at the point satisfying the standards.
(8)Hold the load lever against the full side stopper and the idle side stopper.
(9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
0000001601 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
Timing setting

(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(60deg)
----------
aa=10deg
----------
a=(60deg)
Information:
Checking Backpressure with Manometer/Gauge
Remove the plug from the pressure tap coupling located on the manifold immediately after the engine and install a manometer or pressure gauge. Use a gauge with a minimum range of 0 to 20 kpa (0 to 80 inch of H2O).
After completely warming up the engine, run at no load, wide open throttle (W.O.T.) for 2 to 3 minutes. Record the pressure reading while the engine is running at no load, W.O.T. Repeat 2 to 3 times.
If the observed backpressure is less than 10.20 kPa (41 inch of H2O), the DPF can continue to be operated without further maintenance.
If the backpressure is greater than 10.20 kPa (41 inch of H2O) at the time of installation, contact your Caterpillar dealer. If the backpressure is greater than 10.20 kPa (41 inch of H2O) during a maintenance check, contact your Caterpillar dealer. Your Warranty Rights And Obligations
VERIFIED PRODUCT WARRANTY
Caterpillar Inc. warrants the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owners manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owners manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, a backpressure monitor (if applicable), and other emission-related assemblies. Where a warrantable condition exists, Caterpillar will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor.WARRANTY COVERAGE
For engines used in verified applications, the warranty period will be in years or hours or miles of operation, whichever occurs first, based on the following chart:
Table 1
Engine Type Engine Size Minimum Warranty Period
On-Road Light heavy-duty, 70 to 170 hp, Gross Vehicle Weight Rating (GVWR) less than 19,500 lbs. 5 years or 60,000 miles
Medium heavy-duty, 170 to 250 hp, GVWR from 19,500 lbs. to 33,000 lbs. 5 years or 100,000 miles
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs. 5 years or 150,000 miles
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs., and trucks are:
1. Typically driven over 100,000 miles per year, and
2. Have less than 300,000 miles on the odometer at the time of installation. 2 years, unlimited miles
Off-Road (includes portable engines) and Stationary Under 25 hp, and for constant speed engines rated under 50 hp with rated speeds
Remove the plug from the pressure tap coupling located on the manifold immediately after the engine and install a manometer or pressure gauge. Use a gauge with a minimum range of 0 to 20 kpa (0 to 80 inch of H2O).
After completely warming up the engine, run at no load, wide open throttle (W.O.T.) for 2 to 3 minutes. Record the pressure reading while the engine is running at no load, W.O.T. Repeat 2 to 3 times.
If the observed backpressure is less than 10.20 kPa (41 inch of H2O), the DPF can continue to be operated without further maintenance.
If the backpressure is greater than 10.20 kPa (41 inch of H2O) at the time of installation, contact your Caterpillar dealer. If the backpressure is greater than 10.20 kPa (41 inch of H2O) during a maintenance check, contact your Caterpillar dealer. Your Warranty Rights And Obligations
VERIFIED PRODUCT WARRANTY
Caterpillar Inc. warrants the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owners manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owners manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, a backpressure monitor (if applicable), and other emission-related assemblies. Where a warrantable condition exists, Caterpillar will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor.WARRANTY COVERAGE
For engines used in verified applications, the warranty period will be in years or hours or miles of operation, whichever occurs first, based on the following chart:
Table 1
Engine Type Engine Size Minimum Warranty Period
On-Road Light heavy-duty, 70 to 170 hp, Gross Vehicle Weight Rating (GVWR) less than 19,500 lbs. 5 years or 60,000 miles
Medium heavy-duty, 170 to 250 hp, GVWR from 19,500 lbs. to 33,000 lbs. 5 years or 100,000 miles
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs. 5 years or 150,000 miles
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs., and trucks are:
1. Typically driven over 100,000 miles per year, and
2. Have less than 300,000 miles on the odometer at the time of installation. 2 years, unlimited miles
Off-Road (includes portable engines) and Stationary Under 25 hp, and for constant speed engines rated under 50 hp with rated speeds