Information injection-pump assembly
BOSCH
F 019 Z10 506
f019z10506
ZEXEL
101605-9091
1016059091
Rating:
Service parts 101605-9091 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 506
f019z10506
ZEXEL
101605-9091
1016059091
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
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
3.4
3.35
3.45
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
7.3
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
71.8
70.3
73.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
5.6+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
9.4
8.1
10.7
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.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-5deg b=21deg+-5deg
----------
----------
a=7deg+-5deg b=21deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
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=16deg
----------
a=(100deg)
----------
aa=16deg
----------
a=(100deg)
Information:
Lubricant Viscosity Chart
Commercial Oils
Failure to follow the commercial oil recommendations can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
* API specifications CF-4, CF-4/SH or CF-4/SGThe oil specifications above provide guidelines for the selection of commercial products. They may require shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S). The same viscosity grades are recommended for commercial oils as for CAT oils.Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society if Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information.Caterpillar DI Engines Only
Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur above 0.5% and using API CF-4 oils. Caterpillar requirements reflect this value of 10 times for DI engines.Caterpillar still maintains 20 times TBN value for precombustion chamber (PC) engines when using API CD, CE or CF-4 oil when related to fuel sulfur above 0.5%. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Engines built prior to 1990 can continue to use DEO-CD single grade viscosity oil or commercial oils provided the engine operates to user satisfaction. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and the additives. The additives in the oil will vary according to the properties of the base oil and the environment in which the oil will perform its function.Synthetic base stock oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements specified for a particular compartment. The performance requirements for engines using synthetic oils is API CF-4 with API CE as an alternative.The use of a synthetic base stock oil does NOT allow extension of the oil drain period simply because of the use of synthetic oil. Any drain period extension must be validated by S O S (oil analysis and test evaluation) to ensure no excessive component wear occurs in a particular application.The synthetic oils have naturally low pour points
Commercial Oils
Failure to follow the commercial oil recommendations can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
* API specifications CF-4, CF-4/SH or CF-4/SGThe oil specifications above provide guidelines for the selection of commercial products. They may require shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S). The same viscosity grades are recommended for commercial oils as for CAT oils.Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society if Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information.Caterpillar DI Engines Only
Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur above 0.5% and using API CF-4 oils. Caterpillar requirements reflect this value of 10 times for DI engines.Caterpillar still maintains 20 times TBN value for precombustion chamber (PC) engines when using API CD, CE or CF-4 oil when related to fuel sulfur above 0.5%. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Engines built prior to 1990 can continue to use DEO-CD single grade viscosity oil or commercial oils provided the engine operates to user satisfaction. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and the additives. The additives in the oil will vary according to the properties of the base oil and the environment in which the oil will perform its function.Synthetic base stock oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements specified for a particular compartment. The performance requirements for engines using synthetic oils is API CF-4 with API CE as an alternative.The use of a synthetic base stock oil does NOT allow extension of the oil drain period simply because of the use of synthetic oil. Any drain period extension must be validated by S O S (oil analysis and test evaluation) to ensure no excessive component wear occurs in a particular application.The synthetic oils have naturally low pour points