Information injection-pump assembly
BOSCH
F 019 Z10 040
f019z10040
ZEXEL
107492-2050
1074922050
Rating:
Service parts 107492-2050 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107492-2050
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 040
f019z10040
ZEXEL
107492-2050
1074922050
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
105780-8240
Nozzle
105780-0110
Nozzle holder
105780-2170
Opening pressure
MPa
20.6
Opening pressure
kgf/cm2
210
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0520
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
02
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
01
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
1-3-4-2
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
93
91.4
94.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.5+-0.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
10
8.5
11.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.5)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
93
92
94
Basic
*
Fixing the lever
*
Boost pressure
kPa
44
44
Boost pressure
mmHg
330
330
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.55
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
100.5
96.5
104.5
Fixing the lever
*
Boost pressure
kPa
44
44
Boost pressure
mmHg
330
330
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-0.9
Boost pressure
kPa
21.3
20
22.6
Boost pressure
mmHg
160
150
170
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
85)
Boost pressure
kPa
30.7
30.7
30.7
Boost pressure
mmHg
230
230
230
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=J47 BCL=0.9+-0.1mm
----------
----------
T1=J47 BCL=0.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=23deg+-5deg b=38.5deg+-3deg
----------
----------
a=23deg+-5deg b=38.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At pump speed aa and rack position bb, set the stopper bolt. Confirm non-injection.
(2)After setting stopper bolt, confirm non-injection at pump speed cc.
----------
aa=1450r/min bb=6.2-0.5mm cc=300r/min
----------
a=36.5deg+-5deg b=(33deg)+-5deg
----------
aa=1450r/min bb=6.2-0.5mm cc=300r/min
----------
a=36.5deg+-5deg b=(33deg)+-5deg
0000001301
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 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=1500r/min Ra=R1(12.5)+1.55mm
----------
----------
N1=1500r/min Ra=R1(12.5)+1.55mm
----------
Information:
Crankcase Lubricating Oil
The Lubrication and Maintenance Charts list the normal oil change periods as determined by fuel sulphur content. (Make an initial oil change after the first 500 miles of operation for reconditioned engines.)Use oils which meet Engine Service classification CD or MIL-L-2104C. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines. Diesel Engine Crankcase
Check oil level daily before starting engine and when refueling. Check with the engine either running or stopped as indicated on the oil level gauge. Add oil when the level drops to the add oil mark. Drain the crankcase every 10,000 miles while engine is warm and stopped. If equipped with a 13 qt. supplemental filter system the normal interval can be extended to 15,000 miles. Install drain plug. Diesel Engine Crankcase Lubricating Oil Filter
Change filter element every 10,000 miles. Drain the filter housing by removing drain plug. Loosen bolt on the cover and remove the housing and filter element. Inspect seal and install a new one if necessary. Wash the inside of the filter housing and install a new Caterpillar filter element. After draining crankcase remove filter cap and refill. See page 15 for quantity. Start engine and check for oil leaks at drain plug and filter housing. Diesel Engine Crankcase Breather
Remove breather tube cover and element. Wash with clean solvent or diesel fuel at each oil change period. Inspect seal and replace if necessary. Lubricating Grease
Use Multipurpose-type Grease which contains both 3 to 5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. NLGI No. 1 or No. 0 are suitable for extremely low temperatures.Always clean fittings before lubricating.Fan Pulley Bearing
Lubricate every 10,000 miles. Lubricate through fitting until grease appears at relief fitting on front of fan hub. Wipe off excess grease. Water Pump Bearing
Lubricate every 10,000 miles. Lubricate through fitting until lubricant appears at relief fitting. Earlier engines have no relief fitting. Excess lubricant will appear at end of water pump shaft. Tachometer Drive
Lubricate every 10,000 miles. Remove plug. Install grease fitting and apply one stroke of lubricant through fitting.
The Lubrication and Maintenance Charts list the normal oil change periods as determined by fuel sulphur content. (Make an initial oil change after the first 500 miles of operation for reconditioned engines.)Use oils which meet Engine Service classification CD or MIL-L-2104C. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines. Diesel Engine Crankcase
Check oil level daily before starting engine and when refueling. Check with the engine either running or stopped as indicated on the oil level gauge. Add oil when the level drops to the add oil mark. Drain the crankcase every 10,000 miles while engine is warm and stopped. If equipped with a 13 qt. supplemental filter system the normal interval can be extended to 15,000 miles. Install drain plug. Diesel Engine Crankcase Lubricating Oil Filter
Change filter element every 10,000 miles. Drain the filter housing by removing drain plug. Loosen bolt on the cover and remove the housing and filter element. Inspect seal and install a new one if necessary. Wash the inside of the filter housing and install a new Caterpillar filter element. After draining crankcase remove filter cap and refill. See page 15 for quantity. Start engine and check for oil leaks at drain plug and filter housing. Diesel Engine Crankcase Breather
Remove breather tube cover and element. Wash with clean solvent or diesel fuel at each oil change period. Inspect seal and replace if necessary. Lubricating Grease
Use Multipurpose-type Grease which contains both 3 to 5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. NLGI No. 1 or No. 0 are suitable for extremely low temperatures.Always clean fittings before lubricating.Fan Pulley Bearing
Lubricate every 10,000 miles. Lubricate through fitting until grease appears at relief fitting on front of fan hub. Wipe off excess grease. Water Pump Bearing
Lubricate every 10,000 miles. Lubricate through fitting until lubricant appears at relief fitting. Earlier engines have no relief fitting. Excess lubricant will appear at end of water pump shaft. Tachometer Drive
Lubricate every 10,000 miles. Remove plug. Install grease fitting and apply one stroke of lubricant through fitting.