Information injection-pump assembly
BOSCH
F 019 Z20 060
f019z20060
ZEXEL
106651-4050
1066514050
Rating:
Service parts 106651-4050 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106651-4050
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z20 060
f019z20060
ZEXEL
106651-4050
1066514050
Zexel num
Bosch num
Firm num
Name
106651-4050
F 019 Z20 060
DPICO
INJECTION-PUMP ASSEMBLY
6D22T Q
6D22T Q
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-4420
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
5.1
5.05
5.15
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
12.1
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
136.5
143.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.6
15.9
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.1)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
135
143
Difference in delivery
mm3/st.
8
8
8
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
90
130
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2(R1-2.
1)
Boost pressure
kPa
17.3
16
18.6
Boost pressure
mmHg
130
120
140
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
38
31.3
44.7
Boost pressure
mmHg
285
235
335
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
720
Advance angle
deg.
2.5
2
3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Boost compensator stroke: BCL
(5)Damper spring setting
----------
RT=1 TH=2.8mm BCL=2.1+-0.1mm
----------
----------
RT=1 TH=2.8mm BCL=2.1+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=9deg+-5deg
----------
----------
a=9deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=31deg+-5deg b=36.5deg+-3deg
----------
----------
a=31deg+-5deg b=36.5deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Rack position = bb, set the stopper bolt.
(3)Free (at delivery)
----------
aa=14mm bb=4.9-0.5mm
----------
a=(35.5deg) b=25.5deg+-5deg c=0deg+7deg-5deg
----------
aa=14mm bb=4.9-0.5mm
----------
a=(35.5deg) b=25.5deg+-5deg c=0deg+7deg-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=6+-0.1mm
----------
----------
N1=325r/min Ra=6+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(6deg)
----------
----------
a=(6deg)
Information:
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
****Parts Stock ****
Rework the following engines in dealer parts stock:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
****Affected Product****
This program applies only if the Affected Product is equipped with one of the following Reman Engines:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all engines reworked from dealer parts stock.
This is a 4 hour job for a 3508
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Include the engine serial number(s) of the Reman engine(s) that was/were reworked in the claim.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-250 hrs,
0-3 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
4.0-hours for a 3508.
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Part age/hours is based on engine age/hours.
Include the engine serial number of the Reman engine that was reworked in the claim.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 106651-4050?
Group cross 106651-4050 ZEXEL
Hyundai
Hyundai
Dpico
106651-4050
F 019 Z20 060
INJECTION-PUMP ASSEMBLY
6D22T
6D22T