101607-9430 ZEXEL F 019 Z20 006 BOSCH INJECTION-PUMP ASSEMBLY f019z20006 1016079430

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 006 f019z20006

ZEXEL 101607-9430 1016079430

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Include in #1:

101402-7990 as _

Cross reference number

BOSCH F 019 Z20 006 f019z20006

ZEXEL 101607-9430 1016079430

Zexel num

Bosch num

Firm num

Name

101607-9430

F 019 Z20 006

DPICO

INJECTION-PUMP ASSEMBLY
6D22 Q

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 131424-5120

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 9.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 112 109.2 114.8

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.8+-0.5

Pump speed r/min 450 450 450

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112 111 113

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 85 165

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_05

Adjusting point F

Rack position 7.3+-0.5

Pump speed r/min 335 335 335

Average injection quantity mm3/st. 16 14.5 17.5

Fixing the rack *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Microswitch not operating at delivery. (2)Tolerance for racks not indicated: +-0.05mm. (3)Excess fuel setting for starting: SXL (N = N1) (4)Damper spring setting: DL
----------
SXL=(R1+0.1)+0.2mm N1=350r/min DL=6-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=(1deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=19deg+-5deg b=16.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=54deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(7deg)

Information:

Table 1
Required Parts
Qty Part Number Part Name Former Part Number
1 494-6233 Injector 307-3245(1)
(1) The former part number listed is for reference only and may differ.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
"The improved autolube injector requires a new adjustment sleeve. Follow the procedure below for the selection and adjustment of the sleeve.Changing the Metering Unit
Illustration 1 g06607746
(A) Adjustment Screw
(B) Locknut
(C) Adjustment Sleeve
Table 2
Adjustment Sleeves
Caterpillar Part Number Part Name Output cc Sleeve Color
494-6245 Sleeve 0.25 cc (0.015 cubic inch) Pink
494-6241 Sleeve 0.50 cc (0.030 cubic inch) Red
494-6242 Sleeve 0.750 cc (0.045 cubic inch) Silver
494-6243 Sleeve 1.00 cc (0.06 cubic inch) Gold
494-6244 Sleeve 1.25 cc (0.075 cubic inch) Green The automatic lubrication system offers the ability to change the amount of grease that is supplied per cycle to each grease point. Changing the grease supply amount is completed by adjusting locknut (B) or replacing adjustment sleeve (C) on the injector. See Table 2 for reference.There is a set of color-coded anodized aluminum adjustment sleeves (C) available for various lubrication dispensing amounts. Adjustment sleeves (C) provide an easy way to adjust the output of the injectors and provide a clear indication of the output setting. Adjustment sleeves (C) allow for easy system installation and preventative maintenance.Install adjustment sleeves (C) by doing the following Steps below:
Remove and discard locknut (B).
Place adjustment sleeve (C) on adjustment screw (A).
Tighten adjustment screw (A) to 6.7 N m (60 lb in).