Information injection-pump assembly
BOSCH
F 019 Z10 404
f019z10404
ZEXEL
106671-5140
1066715140
Rating:
Service parts 106671-5140 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1660096605
12.
Open Pre:MPa(Kqf/cm2)
22.6(230)
15.
NOZZLE SET
Include in #1:
106671-5140
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 404
f019z10404
ZEXEL
106671-5140
1066715140
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
132424-0620
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
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
188
186
190
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Solenoid boost comp. OFF
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.4+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12
11
13
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Solenoid boost comp. OFF
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.7
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
125
123
127
Fixing the lever
*
Solenoid boost comp. ON
*
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)Rack limit using stop lever
(5)Damper spring setting
(6)Variable speed specification: idling adjustment
(7)Fix the lever at the full-load position at delivery.
(8)Main spring setting
----------
RT=1 TH=2.6mm
----------
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RT=1 TH=2.6mm
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Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N4=800r/min C4=(5.5)deg t1=2--sec. t2=2--sec.
----------
N1=300r/min N2=900++r/min N3=1100r/min C1=5.5+-0.3deg C2=3++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
----------
L=1-0.2mm N4=800r/min C4=(5.5)deg t1=2--sec. t2=2--sec.
----------
N1=300r/min N2=900++r/min N3=1100r/min C1=5.5+-0.3deg C2=3++deg C3=4--deg P1=0kPa(0kgf/cm2) P2=196kPa(2kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=15.5deg+-5deg b=5.5deg+-5deg
----------
aa=290r/min
----------
a=15.5deg+-5deg b=5.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Accelerator lever angle after setting the accelerator lever stopper bolt
(2)Stopper bolt setting
(3)Use the hole at R = aa
----------
aa=44.5mm
----------
a=33deg+-3deg b=45deg+-5deg c=(2deg)
----------
aa=44.5mm
----------
a=33deg+-3deg b=45deg+-5deg c=(2deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
----------
aa=12mm
----------
a=39.5deg+-5deg b=35.5deg+-5deg
----------
aa=12mm
----------
a=39.5deg+-5deg b=35.5deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=600r/min Ra=12mm
----------
----------
N1=600r/min Ra=12mm
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0000001601 BCS
(A) Screw for precise adjustment
(B) Pre-adjustment screw
(C) Control rack, rack decrease direction
(D) Rack limit
1. Solenoid boost compensator adjustment
(1)Supply DC: V1 to the solenoid terminals and confirm solenoid operation.
(2)With the solenoid ON, calculate L1 from the value of R1. [L1 = La - (10.5 - R1) +-0.2]
(3)Adjust (B) to obtain L1.
(4)Assemble the solenoid to the governor.
(5)With the solenoid ON, readjust (B) so that R1 is within the allowance a.
(6)With the solenoid OFF, perform all governor adjustments except rack limit adjustment.
(7)Set the pump speed at N1 and turn the solenoid ON.
(8)Adjust (A) so that R1 is within the allowance range a.
(9)Set the pump speed at N1 and fix the load lever in the full position
(10)Turn the solenoid switch ON and OFF several times and confirm that the difference in rack positions is within L2.
(11)Set the rack limit.
(12)Stamp the solenoid valve.
----------
V1=24V N1=300r/min N2=0r/min R1=9.7mm a=+-0.5mm La=28mm L1=27.2+-0.2mm L2=3.5~5mm
----------
----------
V1=24V N1=300r/min N2=0r/min R1=9.7mm a=+-0.5mm La=28mm L1=27.2+-0.2mm L2=3.5~5mm
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0000001701 LEVER
(A) Load lever (for cruise control)
(B) idle stopper bolt
(C) Accelerator lever stopper bolt
For (D) Accelerator lever
(E) Accelerator lever
I:Idle
Accelerator lever, stopper bolt setting procedure
(1)Position the load lever (A; for autocruise) against the idle stopper bolt (B) and fix.
(2)Screw in the accelerator lever stopper bolt (C).
(3)Back off the stopper bolt (C) 1 turn from the position where the accelerator lever (D) contacts the load lever (A) and set.
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
Active Diagnostic Codes
Diagnostic codes are used by the 3176 system to warn the vehicle operator of a problem and indicate to the service technician the nature of the problem. Some codes are used only to record an event, and do not indicate problems.An ACTIVE Diagnostic code represents a problem that should be investigated and corrected AS SOON AS POSSIBLE. Repairing the cause of an ACTIVE code will cause the code to be cleared from the ACTIVE Diagnostic Code screen.When an ACTIVE code is generated, the 3176 Diagnostic Lamp will turn ON and remain ON, blinking every five seconds. If the condition generating the fault occurs only for a brief moment, the lamp will go OFF after five seconds and the fault will be LOGGED. After a problem has been investigated/corrected, the related diagnostic code should be cleared from memory.ACTIVE codes may be viewed using either of the electronic service tools (ECAP or DDT), and may also be viewed using the diagnostic lamp and cruise control switches. The Diagnostic Lamp should not be confused with the Warning Lamp which is used with 3176 Caterpillar Engine Protection. Some troubleshooting procedures, such as disconnection of a sensor may cause diagnostic codes. Make sure all diagnostic codes are noted prior to the start of the troubleshooting procedure to avoid confusion.Using The ECAP Or DDT To Display Active Codes
1. With key OFF, install an ECAP or DDT into the 3176 system.2. Turn key ON (engine does not need to be started to view codes).3. Refer to the Operating Manual and Special Instructions for the service tool (listed under 3176 Service Tools) to read the code(s). On the ECAP, the display menu will direct you to the proper screen to display diagnostic messages similar to the example below.Using The Cruise Control Switches To Display Active Codes:
1. Turn key ON (engine does not need to be started to view codes).2. The 3176 Diagnostic Lamp will turn ON for five seconds, blink OFF, turn ON again for five seconds, then OFF for five seconds. At the end of that time, the lamp will begin to flash the first number of the two-digit code (count the flashes). After two seconds OFF, then it will flash the second digit. If two or more codes are present, they will follow the first after a few seconds and be displayed in the same manner.3. Active diagnostic codes may be displayed at any time by suing cruise control switches. With key ON or engine running, turn the cruise control ON/OFF switch to OFF, and move the SET/RESUME switch to RESUME position. Once the codes begin to flash the switch may be released. The 3176 Diagnostic Lamp will flash out all the codes that are currently ACTIVE, or intermittent codes that have occurred since the key was turned ON.
Example ECAP Screen: "Display ACTIVE Diagnostic Messages"Logged Diagnostic Codes
When an ECM generates a diagnostic code, it usually logs the code in permanent memory within the ECM. The time the code occurred (in hours on
Diagnostic codes are used by the 3176 system to warn the vehicle operator of a problem and indicate to the service technician the nature of the problem. Some codes are used only to record an event, and do not indicate problems.An ACTIVE Diagnostic code represents a problem that should be investigated and corrected AS SOON AS POSSIBLE. Repairing the cause of an ACTIVE code will cause the code to be cleared from the ACTIVE Diagnostic Code screen.When an ACTIVE code is generated, the 3176 Diagnostic Lamp will turn ON and remain ON, blinking every five seconds. If the condition generating the fault occurs only for a brief moment, the lamp will go OFF after five seconds and the fault will be LOGGED. After a problem has been investigated/corrected, the related diagnostic code should be cleared from memory.ACTIVE codes may be viewed using either of the electronic service tools (ECAP or DDT), and may also be viewed using the diagnostic lamp and cruise control switches. The Diagnostic Lamp should not be confused with the Warning Lamp which is used with 3176 Caterpillar Engine Protection. Some troubleshooting procedures, such as disconnection of a sensor may cause diagnostic codes. Make sure all diagnostic codes are noted prior to the start of the troubleshooting procedure to avoid confusion.Using The ECAP Or DDT To Display Active Codes
1. With key OFF, install an ECAP or DDT into the 3176 system.2. Turn key ON (engine does not need to be started to view codes).3. Refer to the Operating Manual and Special Instructions for the service tool (listed under 3176 Service Tools) to read the code(s). On the ECAP, the display menu will direct you to the proper screen to display diagnostic messages similar to the example below.Using The Cruise Control Switches To Display Active Codes:
1. Turn key ON (engine does not need to be started to view codes).2. The 3176 Diagnostic Lamp will turn ON for five seconds, blink OFF, turn ON again for five seconds, then OFF for five seconds. At the end of that time, the lamp will begin to flash the first number of the two-digit code (count the flashes). After two seconds OFF, then it will flash the second digit. If two or more codes are present, they will follow the first after a few seconds and be displayed in the same manner.3. Active diagnostic codes may be displayed at any time by suing cruise control switches. With key ON or engine running, turn the cruise control ON/OFF switch to OFF, and move the SET/RESUME switch to RESUME position. Once the codes begin to flash the switch may be released. The 3176 Diagnostic Lamp will flash out all the codes that are currently ACTIVE, or intermittent codes that have occurred since the key was turned ON.
Example ECAP Screen: "Display ACTIVE Diagnostic Messages"Logged Diagnostic Codes
When an ECM generates a diagnostic code, it usually logs the code in permanent memory within the ECM. The time the code occurred (in hours on