Information injection-pump assembly
BOSCH
F 019 Z10 992
f019z10992
ZEXEL
101606-0582
1016060582
ISUZU
1156035012
1156035012
Rating:
Service parts 101606-0582 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-432-1
12.
Open Pre:MPa(Kqf/cm2)
14.
NOZZLE
Include in #1:
101606-0582
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6220
as _
Cross reference number
BOSCH
F 019 Z10 992
f019z10992
ZEXEL
101606-0582
1016060582
ISUZU
1156035012
1156035012
Zexel num
Bosch num
Firm num
Name
F 019 Z10 992
1156035012 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-T * K 14BF INJECTION PUMP ASSY PE6AD PE
6BG1-T * K 14BF INJECTION PUMP ASSY PE6AD PE
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
134424-4120
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
4.2
4.15
4.25
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
10.3
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
95
93.5
96.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
112
112
Boost pressure
mmHg
840
840
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.8+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
12
10.7
13.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R1-1.05
Boost pressure
kPa
53.3
49.3
57.3
Boost pressure
mmHg
400
370
430
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R1(10.3)
Boost pressure
kPa
98.6
91.9
105.3
Boost pressure
mmHg
740
690
790
Timer adjustment
Pump speed
r/min
1300++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1300.
Do not advance until starting N = 1300.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
1
1
1
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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
(5)Boost compensator stroke: BCL
----------
K=10 BCL=1.05+-0.1mm
----------
----------
K=10 BCL=1.05+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-5deg b=23deg+-5deg
----------
----------
a=7deg+-5deg b=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=53deg+-5deg b=45deg+-5deg
----------
----------
a=53deg+-5deg b=45deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(1)Before adjusting the governor and the boost compensator, temporarily tighten the screw to the specified torque. (Do not damage the thread.)
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=29.4~39.2N-m(3~4kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=29.4~39.2N-m(3~4kgf-m)
----------
Timing setting
(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=6deg
----------
a=(90deg)
----------
aa=6deg
----------
a=(90deg)
Information:
Engine Identification
Caterpillar engines are identified with Serial Numbers, Performance Specification Numbers (fuel system settings) and Arrangement Numbers. In some cases Modification Numbers are also used.These numbers are shown on the serial number plate mounted on the engine.Electronic engines have the fuel setting information numbers stored in the personality module and can be read by using Caterpillar service tools (i.e. ECAP or DDT).Caterpillar dealers need all of these numbers to determine which components were included on the engine when it was assembled at the factory. This permits accurate identification of replacement part numbers.Serial Number Plate
Located on the right rear side of the cylinder block.Information Plate
Located on the valve cover.Reference Numbers
Ordering Parts
Quality Caterpillar replacement parts are available from Caterpillar dealers throughout North America and the world. Their parts stocks are up to date and include all parts normally required to protect your investment in Caterpillar engines.* When ordering parts, your order should specify the part number, part name, quantity and serial number, arrangement number and modification number of the engine for which the parts are needed. If in doubt about the part number, please provide your dealer with a complete description of the needed item.* When maintenance or repair is needed for your Caterpillar engine, be prepared to give the dealer all the information that is provided on the Information Plate, described in this manual.* Discuss the problem with the dealer, such as; when it occurs, what happens, etc. This will help the dealer in troubleshooting and solving the problem faster.Fill in blanks for future reference.Chassis Serial No. ____________________Engine Model ____________________Engine Serial No. ____________________Engine Arrangement No. ____________________Modification No. ____________________Engine Low Idle RPM ____________________Engine Full Load RPM ____________________Performance Specification No. ____________________Governor Group No. ____________________Fuel Filter No. ____________________Primary Fuel Filter No. ____________________Lubrication Oil Filter Element No. ____________________Auxiliary Oil Filter Element No. ____________________Supplemental Coolant Additive Maintenance Element No. 9N3368Supplemental Coolant Additive Precharge Element No. 7E6013Air Cleaner Element No. ____________________Fan Drive Belt Set No. ____________________Alternator Belt No. ____________________Lube System Capacity (Total) ____________________Cooling System Capacity (Total) ____________________
Caterpillar engines are identified with Serial Numbers, Performance Specification Numbers (fuel system settings) and Arrangement Numbers. In some cases Modification Numbers are also used.These numbers are shown on the serial number plate mounted on the engine.Electronic engines have the fuel setting information numbers stored in the personality module and can be read by using Caterpillar service tools (i.e. ECAP or DDT).Caterpillar dealers need all of these numbers to determine which components were included on the engine when it was assembled at the factory. This permits accurate identification of replacement part numbers.Serial Number Plate
Located on the right rear side of the cylinder block.Information Plate
Located on the valve cover.Reference Numbers
Ordering Parts
Quality Caterpillar replacement parts are available from Caterpillar dealers throughout North America and the world. Their parts stocks are up to date and include all parts normally required to protect your investment in Caterpillar engines.* When ordering parts, your order should specify the part number, part name, quantity and serial number, arrangement number and modification number of the engine for which the parts are needed. If in doubt about the part number, please provide your dealer with a complete description of the needed item.* When maintenance or repair is needed for your Caterpillar engine, be prepared to give the dealer all the information that is provided on the Information Plate, described in this manual.* Discuss the problem with the dealer, such as; when it occurs, what happens, etc. This will help the dealer in troubleshooting and solving the problem faster.Fill in blanks for future reference.Chassis Serial No. ____________________Engine Model ____________________Engine Serial No. ____________________Engine Arrangement No. ____________________Modification No. ____________________Engine Low Idle RPM ____________________Engine Full Load RPM ____________________Performance Specification No. ____________________Governor Group No. ____________________Fuel Filter No. ____________________Primary Fuel Filter No. ____________________Lubrication Oil Filter Element No. ____________________Auxiliary Oil Filter Element No. ____________________Supplemental Coolant Additive Maintenance Element No. 9N3368Supplemental Coolant Additive Precharge Element No. 7E6013Air Cleaner Element No. ____________________Fan Drive Belt Set No. ____________________Alternator Belt No. ____________________Lube System Capacity (Total) ____________________Cooling System Capacity (Total) ____________________