Information injection-pump assembly
BOSCH
9 400 613 490
9400613490
ZEXEL
101401-1580
1014011580
Rating:
Service parts 101401-1580 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME016315
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 490
9400613490
ZEXEL
101401-1580
1014011580
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8720
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
1-3-4-2
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
75.5
73.9
77.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
14.8
13.5
16.1
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
75.5
74.5
76.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.3
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
96.2
92.2
100.2
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
6)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
47.8
43.8
51.8
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-0.4
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
33.2
29.2
37.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
R2-0.4
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
R2(R1-0.
6)
Boost pressure
kPa
23.3
23.3
23.3
Boost pressure
mmHg
175
175
175
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
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=G57 BCL=0.4+-0.1mm
----------
----------
T1=G57 BCL=0.4+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(38deg)+-3deg
----------
aa=40mm
----------
a=26deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Use the hole at R = aa
(2)Free (at delivery)
(3)Rack position corresponding to bb
(4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). Confirm non-injection.
(5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.6-0.5mm ee=325r/min ff=8mm
----------
a=26.5deg+-5deg b=16deg+-5deg c=33deg+-5deg
----------
aa=40mm bb=16mm cc=1700r/min dd=6.6-0.5mm ee=325r/min ff=8mm
----------
a=26.5deg+-5deg b=16deg+-5deg c=33deg+-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=1025r/min Ra=8.5+-0.1mm
----------
----------
N1=1025r/min Ra=8.5+-0.1mm
----------
Timing setting
(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)-
----------
aa=11.5deg
----------
a=(130deg)
----------
aa=11.5deg
----------
a=(130deg)
Information:
REM07-12
Reman
July 2007 APPEARANCE CHANGE TO CAT REMAN DIFN NOZZLES
Announcement
The Caterpillar Remanufactured Products Group announces a change on selected Cat? Reman DIFN nozzles. Currently, the nozzles include an edge filter located in the adapter. Effective on 07/02/07, Reman will not include edge filters in nozzles as an improvement to the source of debris caused by the edge filter movement and or chipping the corners when pressing the filter inside the adapter. This change will not alter fit or performance in any way.
Part Numbers Impacted
The table below lists part numbers impacted by this change.
Features And Benefits
Cat Remanufactured fuel nozzles 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 nozzles. Cat Remanufactured fuel nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured Engine Components is simple, visual, and requires no special tools. Consult your Core Acceptance Guide for complete details.
Warranty
Please consult the appropriate warranty statement for your area.
Core Management
Please 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. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail.
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 Dealer website https://reman.cat.com
If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman
Technical Help Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0782 CATERPILLAR? ?2007 Caterpillar