Information injection-pump assembly
BOSCH
F 019 Z10 130
f019z10130
ZEXEL
106682-9780
1066829780

Rating:
Service parts 106682-9780 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-9780
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 130
f019z10130
ZEXEL
106682-9780
1066829780
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131424-7120
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
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
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
14.3
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
348
345
351
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
76
76
Boost pressure
mmHg
570
570
Remarks
Standard point A's rack position same as row R
Standard point A's rack position same as row R
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
20
18.5
21.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-2.8
Boost pressure
kPa
6.7
4
9.4
Boost pressure
mmHg
50
30
70
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(15.8)
Boost pressure
kPa
62.7
56
69.4
Boost pressure
mmHg
470
420
520
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT for 106684-4310
(3)Boost compensator stroke: BCL
(4)Set the No 1 idle sub spring.
(5)Set the 2nd idle sub spring.
(6)Rack difference between N = N1 and N = N2
----------
K=25 BCL=2.8+-0.1mm N1=1000r/min N2=700r/min
----------
----------
K=25 BCL=2.8+-0.1mm N1=1000r/min N2=700r/min
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=42deg+-5deg b=27deg+-5deg
----------
----------
a=42deg+-5deg b=27deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)-
----------
aa=0r/min bb=1-0.5mm
----------
a=29deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=29deg+-5deg b=(73deg)
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:
Engine Oil Pressure
The sensor utilizes engine oil pressure and engine speed to perform low engine oil pressure detection for diagnostic and annunciation.The graph below illustrates the limits of low engine oil pressure diagnostic and annunciation. The output from the ECM can be used to drive a relay or a lamp to annunciate Low Oil Pressure conditions.
Oil Pressure ParametersLow Oil Pressure Alarm
Oil pressure sensor location.The sensor is mounted in the front of the engine cylinder block with oil lines connected to the switch. Low engine oil pressure closes the switch.The oil pressure switch senses oil pressure at the bearing oil gallery. No resetting procedure is required. Switches may close at 48 to 62 kPa (7 to 9 psi) below actual trip point.Oil Pressure Sensor Failure
When the sensor output is open, shorted to ground or supply, or measured oil pressure reading is out of specification, a sensor failure may have occurred.The ECM will detect the oil pressure sensor failure and through the diagnostic lamp warn the user about the oil pressure sensor failure. The oil pressure related strategies will be disabled. The oil pressure sensor failure will not cause an engine shut down, power derating, or any engine speed change.Speed Sensing Loss Alarm
When the engine speed sensor can no longer sense engine speed, an alarm and diagnostic code entry will occur. If the ECM can not detect any engine speed, the engine will shut down.Manual Fuel Shutoff Lever
Do not use the emergency shutoff control for a normal stopping procedure.
Manual shutdown shaft with lever location.A manual shutdown shaft is provided to override the governor solenoid. This shutdown will only move the fuel control linkage to the fuel OFF position to starve the engine of fuel. It does not shut off the air inlet.Engine Shutoff Controls
Secondary shutoff controls may be electrically, mechanically or hydraulically operated. Familiarize yourself with the types and locations of the shutoff controls, the conditions which cause each control to function, and the resetting procedure required to start your engine.The shutoff controls should be tested every 1000 hours by authorized Caterpillar dealer personnel.Always determine the cause of the shutdown, and have the necessary repairs made before restarting the engine.Shutoff Solenoid Failure
When the shutoff solenoid output is open or shorted to ground or supply, a failure may have occurred.The ECM will detect open or short condition of the shutoff solenoid. If the solenoid is failed "open", the engine will shut down.The shutoff solenoid failure will cause the engine to shut down, but the pilot or service personnel can mechanically reposition the shutoff solenoid and restart the engine.Cold Start Strategy
This feature utilizes the coolant temperature sensor input to improve low temperature engine starting and warm-up. It provides quicker cold starts, smoke cleanup, reduces battery "deep" cycling and extends engine life. The engine timing is fixed at 19.5 degrees. Engine block heaters are provided to maintain minimum engine temperature when the engine is not running.When the coolant temperature is below 60°C (140°F), the cold start strategy is activated using the following parameters
The sensor utilizes engine oil pressure and engine speed to perform low engine oil pressure detection for diagnostic and annunciation.The graph below illustrates the limits of low engine oil pressure diagnostic and annunciation. The output from the ECM can be used to drive a relay or a lamp to annunciate Low Oil Pressure conditions.
Oil Pressure ParametersLow Oil Pressure Alarm
Oil pressure sensor location.The sensor is mounted in the front of the engine cylinder block with oil lines connected to the switch. Low engine oil pressure closes the switch.The oil pressure switch senses oil pressure at the bearing oil gallery. No resetting procedure is required. Switches may close at 48 to 62 kPa (7 to 9 psi) below actual trip point.Oil Pressure Sensor Failure
When the sensor output is open, shorted to ground or supply, or measured oil pressure reading is out of specification, a sensor failure may have occurred.The ECM will detect the oil pressure sensor failure and through the diagnostic lamp warn the user about the oil pressure sensor failure. The oil pressure related strategies will be disabled. The oil pressure sensor failure will not cause an engine shut down, power derating, or any engine speed change.Speed Sensing Loss Alarm
When the engine speed sensor can no longer sense engine speed, an alarm and diagnostic code entry will occur. If the ECM can not detect any engine speed, the engine will shut down.Manual Fuel Shutoff Lever
Do not use the emergency shutoff control for a normal stopping procedure.
Manual shutdown shaft with lever location.A manual shutdown shaft is provided to override the governor solenoid. This shutdown will only move the fuel control linkage to the fuel OFF position to starve the engine of fuel. It does not shut off the air inlet.Engine Shutoff Controls
Secondary shutoff controls may be electrically, mechanically or hydraulically operated. Familiarize yourself with the types and locations of the shutoff controls, the conditions which cause each control to function, and the resetting procedure required to start your engine.The shutoff controls should be tested every 1000 hours by authorized Caterpillar dealer personnel.Always determine the cause of the shutdown, and have the necessary repairs made before restarting the engine.Shutoff Solenoid Failure
When the shutoff solenoid output is open or shorted to ground or supply, a failure may have occurred.The ECM will detect open or short condition of the shutoff solenoid. If the solenoid is failed "open", the engine will shut down.The shutoff solenoid failure will cause the engine to shut down, but the pilot or service personnel can mechanically reposition the shutoff solenoid and restart the engine.Cold Start Strategy
This feature utilizes the coolant temperature sensor input to improve low temperature engine starting and warm-up. It provides quicker cold starts, smoke cleanup, reduces battery "deep" cycling and extends engine life. The engine timing is fixed at 19.5 degrees. Engine block heaters are provided to maintain minimum engine temperature when the engine is not running.When the coolant temperature is below 60°C (140°F), the cold start strategy is activated using the following parameters