Information injection-pump assembly
BOSCH
F 019 Z10 882
f019z10882
ZEXEL
106871-4081
1068714081
Rating:
Service parts 106871-4081 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:
106871-4081
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 882
f019z10882
ZEXEL
106871-4081
1068714081
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
134424-1320
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
9.5
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
118
114.5
121.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
F
Rack position
5.8+-0.5
Pump speed
r/min
450
450
450
Each cylinder's injection qty
mm3/st.
17
15.3
18.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.5)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
118
117
119
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.5)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
124
118.8
129.2
Difference in delivery
mm3/st.
10.4
10.4
10.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
6.1+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
20
17
23
Fixing the rack
*
Remarks
(check)
(check)
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
145
125
165
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
5
4.5
5.5
Timer adjustment_04
Pump speed
r/min
(1150)
Advance angle
deg.
6.5
6
7
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Adjust with speed control lever at full position (minimum-maximum speed specification)
(2)Lever ratio: RT
(3)Target shim dimension: TH
(4)Tolerance for racks not indicated: +-0.05mm.
(5)Excess fuel setting for starting: SXL
(6)Damper spring setting
(7)Adjust with the load control lever in the full position (variable speed specification).
(8)When air cylinder is operating.
----------
RT=1 TH=2.3mm SXL=(R1+0.2)+-0.1mm
----------
----------
RT=1 TH=2.3mm SXL=(R1+0.2)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)-
(2)Air cylinder's adjustable range
(3)Pump speed = aa
(4)Pump speed = bb
(5)Pump speed cc
----------
aa=1200r/min bb=275r/min cc=800r/min
----------
a=(13.5deg) b=13.5deg+-5deg c=22.5deg+-5deg d=7.5deg+-5deg
----------
aa=1200r/min bb=275r/min cc=800r/min
----------
a=(13.5deg) b=13.5deg+-5deg c=22.5deg+-5deg d=7.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=26deg+-3deg
----------
----------
a=10deg+-5deg b=26deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
(2)Rack position bb
(3)Free (at delivery)
----------
aa=4-0.5mm bb=11.7mm
----------
a=21.5deg+-5deg b=43deg+7deg-5deg c=(10.5deg)
----------
aa=4-0.5mm bb=11.7mm
----------
a=21.5deg+-5deg b=43deg+7deg-5deg c=(10.5deg)
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=5.6+-0.1mm
----------
----------
N1=325r/min Ra=5.6+-0.1mm
----------
0000001601 2-STAGE CHANGEOVER DEVICE
RFD governor 2 stage changeover mechanism adjustment outline
(A) Bolt
(B) bolt
(c) Nut
(D) Return spring
(E) Bolt
(F) Bolt
(G) Screw
(H) Bolt
(I) Load lever
(J) Speed lever
(K) Air cylinder
(M Air inlet
Figure 1 is only for reference. Lever shape, etc, may vary.
1. Minimum-maximum speed specification adjustment (when running)
(a) Without applying air to the air cylinder, loosen bolts (A) and (B).
(1)High speed return L setting
(a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed.
(b) Determine the rack position in the vicinity of Rf using the full load lever.
(c) Increase speed and confirm return distance L.
(d) Adjust using the tension lever bolt to obtain L.
(2)Setting full load rack position Rf
(a) Move the load control lever to the full side.
(b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix.
(3)Setting the beginning of high speed operation Nf
(a) Adjust using bolt (E) so that Nf can be obtained, and then fix.
(4)Idle control setting (Re, Ni, Rc)
(a) Set the speed at Ns + 200r/min and move the load control lever to the idle side.
(b) Fix the lever in the position where Re can be obtained.
(c) Next, decrease speed to Ni and screw in the idle spring.
(d) Adjust to obtain rack position Ri.
(e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0.
(f) Confirm protrusion position Rc at idle.
(5)Damper spring adjustment
(a) Increase speed and set the speed at the rack position Rd - 0.1 mm
(b) Set using the damper spring so that the rack position Rd can be obtained.
(c) When Rd is not specified, Rd = Ri - 0.5 mm.
(6)High speed droop confirmation
(a) Return the load control lever to the full load lever position.
(b) Increase the speed and confirm that Rf can be obtained at Nf r/min.
(c) Confirm that speed is Nh at rack position Rh.
2. Variable speed specification adjustment (at operation)
(a) Remove return spring (D).
(b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder.
(c) Perform the following adjustment in this condition.
(1)Setting full load rack position Rf'
(a) Pull the load lever to the idle side.
(b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.)
(2)Setting full speed Nf'
(a) Adjust using bolt (B) so that Nf can be obtained, and then fix.
(3)Low speed side setting
(a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix.
3. Bolt (A) adjustment
(1)Install return spring (D) and perform the adjustments below at air pressure 0.
(a) Set at speed Nf using bolt (E).
(b) Screw in bolt (A).
(c) Screw in 1 more turn from the speed lever contact position
(d) Fix bolt (A).
(e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor.
4. Lever operation confirmation using the air cylinder
(1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder.
(2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
REM06-41
Reman
November 2006 REMAN FUEL INJECTORS FOR VARIOUS MACHINE, INDUSTRIAL AND ON-HIGHWAY TRUCK APPLICATIONS AnnouncementThe Remanufacturing Division announces the addition of the following Remanufactured Fuel Injectors to complement the existing product offerings for various machine, industrial and on-highway truck applications. CoverageThe addition of these Reman Fuel Injectors provides dealers with a lower cost repair option. The table below lists coverage by part number.
Reman Part Number New Part Number Engine Model Part Name
10R3071 2490697 C13 Injector Gp- Fuel
10R3147 2490712 C11 Injector Gp- Fuel
10R3262 2490713 C11 Injector Gp- Fuel
10R3263 2530614 C15 Injector Gp- Fuel
10R3264 2530615 C15 Injector Gp- Fuel
10R3266 2530617 C27 Injector Gp- Fuel Features and BenefitsCat? Remanufactured fuel injectors offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured fuel injectors. Cat Remanufactured fuel injectors provide immediate, off-the-shelf availability at a fraction of the new price.
Features Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Caterpillar parts distribution system
Customer access regardless of location
Off-the-shelf availability
Downtime reduced through exchange product
Same-as-new Caterpillar warranty
Consistent support
Core AcceptanceCore Acceptance Criteria for Caterpillar? Remanufactured fuel injectors is a simple, visual inspection, and requires no special tools. Consult our Core Acceptance Guide online for complete details.WarrantyPlease consult the appropriate warranty statement for your area.Core ManagementPlease refer to the Caterpillar? Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date.For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman website at https://reman.cat and click on Procedures and Policies (listed under Reman Program Information). If you have any questions regarding core return processing, feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928 or use our e-mail address -- reman_core_operations. For assistance with technical questions, call the Peoria Reman Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our e-mail address -- Reman_Help.
PELJ0719 CATERPILLAR? ?2006 Caterpillar