101607-6170 ZEXEL F 019 Z10 381 BOSCH INJECTION-PUMP ASSEMBLY f019z10381 1016076170

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 381 f019z10381

ZEXEL 101607-6170 1016076170

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Buy INJECTION-PUMP ASSEMBLY 101607-6170 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-6170 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9440

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5070

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7062

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/21.6(220)

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0230

Include in #1:

101492-4041 as _

101607-6170 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 381 f019z10381

ZEXEL 101607-6170 1016076170

Zexel num

Bosch num

Firm num

Name

101607-6170
101607-6172

F 019 Z10 381

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 131424-8420

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 3.2 3.2 3.25

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 12

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 85.1 82.5 87.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 85.1 84.1 86.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.85

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 99.9 95.9 103.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 2.5 2.5 3.5

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 6 5.5 6.5

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=G43
----------

Speed control lever angle

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

----------
a=18.5deg+-5deg b=(42deg)+-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 delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(42deg)+-3deg c=18.5deg+-5deg

0000001601 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=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

0000001701 MICRO SWITCH

Adjust the bolt to obtain the following lever position when the micro-switch is OFF. 1. Microswitch adjustment (OPEN type) Confirm with the lever angle at full. (1)Speed N1 (2)Rack position Ra
----------
N1=1675r/min Ra=8.5+-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=10deg
----------
a=(3deg)

Information:

Table 1
CCM Error Codes
CCM Error Code Explanation Action Required
E00 No fault, normal operating mode None
E01 Setpoint (EEPROM) fault CCM passwords, unit addresses, or communication setups are corrupted. Reprogram from Phone-Book and Utilities pull-down menus.
E02 M5X message error Check customer generated M5X code
E03 Memory backup battery is weak Change battery. Refer to Operation and Maintenance Manual, "Battery - Replace"
E04 RS-232C link short circuit fault Check RS-232C cable, PC port, and CCM port
E05 Internal buffer overflow on RS-232C or Data Link fault Possibly caused by a slower than acceptable communication rate from the RS-232C port or an open CAT Data Link connection during RS-232C transmission. Increase communication rate and check CAT Data Link wires.
E06 Invalid CAT Data Link Message fault Caused by:
1. Too much traffic on CAT Data Link.
2. CAT Data Link wires too long.
Remove ECAP or other Caterpillar electronic service tool devices overloading CAT Data Link and check CAT Data Link wires.
E07 Miscellaneous CAT Data Link Fault Caused by:
1. (+/-) CAT Data Link shorted to (+/-) battery.
2. Internal hardware fault in CCM.
Check CAT Data Link wiring and then replace CCM if wiring is good.
E08 RS-232C link message fault (parity, data size) Check RS-232C protocol (communication rate, data bits, stop bits, parity) of CCM and PC.
888 Internal CCM fault Replace the CCM.