Information injection-pump assembly
BOSCH
F 019 Z10 393
f019z10393
ZEXEL
101607-6461
1016076461
Rating:
Service parts 101607-6461 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076952
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Cross reference number
BOSCH
F 019 Z10 393
f019z10393
ZEXEL
101607-6461
1016076461
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
131424-8420
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor 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
11.7
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
77.4
75.1
79.7
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(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.4
76.4
78.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.55
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
87.7
83.7
91.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
56
52
60
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
E
Rack position
(R1+0.5)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
87.6
83.6
91.6
Fixing the lever
*
Injection quantity adjustment_07
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
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
6
5.5
6.5
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)RACK LIMIT
----------
T1=H50
----------
----------
T1=H50
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=(42deg)+-3deg
----------
----------
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
----------
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 MICRO SWITCH
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
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
----------
----------
N1=1675r/min Ra=8.5+-0.1mm
----------
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
----------
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------
0000001701 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
----------
----------
b=(42deg)+-3deg c=18.5deg+-5deg
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=(2deg)
----------
aa=10deg
----------
a=(2deg)
Information:
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.
Illustration 1 g01006397
Typical example (1) Bolt (2) Washer (3) Air inlet cover
Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2) .
Disconnect the electrical connector of the injection actuation pressure control valve (7). Remove the injection actuation pressure control valve (7) from the pump. Retain the injection actuation pressure control valve (7) for the reinstallation.Note: Modifications to the tools may need to be made in order to reduce interference with engine components.
Illustration 2 g01007381
Modified 2P-5494 crowfoot wrench
Remove the hose assembly (5), the connector (8), and the elbow (6). Discard these parts.
Illustration 3 g01006381
(4) HEUI pump (5) Flexible oil line (6) Elbow (7) Injection actuation pressure control valve (8) ConnectorInstallation of the 240-0716 Tube Kit
Illustration 4 g01006407
(4) HEUI pump (7) Injection actuation pressure control valve (9) Connector (10) Clip (11) Washer (12) Bolt (13) Spacer (14) Tube assembly (15) O-ring (16) O-ring (17) Elbow
Illustration 5 g01006437
(7) Injection actuation pressure control valve (9) Connector (15) O-ring (16) O-ring (17) Elbow
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the connector (9). Install the O-ring (16) on the connector (9). Thread the connector (9) into the port on the cylinder head by hand. Tighten to 48 + 5 N m (35 + 4 lb ft).
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the elbow (17). Install the O-ring (16) on the elbow (17).
Back off the jam nut on the elbow (17) to the top of the threads on the elbow assembly (17). Push the washer tightly against the jam nut. Check that the washer is as tight as possible. Thread the elbow assembly (17) into the port of the HEUI pump (4). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (4). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.
Align the tube assembly (14) with the connector (9) and the elbow (17). Loosely thread each end of the tube assembly (14) onto the connector (9) and the elbow (17). Position the elbow (17) in order to not create stress in the tube assembly (14) .
Attach the clip (10) to the tube assembly (14). The flat side of the clip (10) must be toward the air inlet cover. Place the washer (11) onto the bolt