Information injection-pump assembly
BOSCH
F 01G 09U 01F
f01g09u01f
ZEXEL
101403-9041
1014039041

Rating:
Service parts 101403-9041 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-19D20
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 01F
f01g09u01f
ZEXEL
101403-9041
1014039041
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
134424-4120
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
1-3-4-2
Pre-stroke
mm
3.2
3.15
3.25
Rack position
Point A R=A
Point A R=A
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
14.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
98.5
96.9
100.1
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10
8.2
11.8
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(14.1)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
98.5
97.5
99.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
60.7
60.7
Boost pressure
mmHg
455
455
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
112
108
116
Fixing the lever
*
Boost pressure
kPa
60.7
60.7
Boost pressure
mmHg
455
455
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2-1.65
Boost pressure
kPa
14
12.7
15.3
Boost pressure
mmHg
105
95
115
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R2(R1-0.
15)
Boost pressure
kPa
47.3
47.3
47.3
Boost pressure
mmHg
355
355
355
Timer adjustment
Pump speed
r/min
780--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
730
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1550
Advance angle
deg.
5.7
5.2
6.2
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
7
6.5
7.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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=N79 BCL=1.65+-0.1mm
----------
----------
T1=N79 BCL=1.65+-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=32mm
----------
a=71deg+-5deg b=41deg+-3deg
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=15mm
----------
a=10deg+-5deg b=29deg+-5deg
----------
aa=15mm
----------
a=10deg+-5deg b=29deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=8deg
----------
a=(50deg)
----------
aa=8deg
----------
a=(50deg)
Information:
Fuel Recommendations
Use only fuel as recommended in this section. The fuels recommended for use in Caterpillar engines are No.2-D diesel fuel and No.2-D fuel oil. No.2-D is preferred, although No.1 grades are acceptable. The following fuel specifications meet Caterpillar requirements. These fuel characteristics should be considered when procuring fuel for use in Caterpillar diesel engines. Caterpillar Diesel Engines are capable of burning a wide range of distillate fuels. The use of clean, stable blends of distillate fuel which meet the following requirements will provide quality engine service life. Filterability
Clean fuels should have no more than 0.1% of sediment and water. Storage of fuel for extended periods of time can cause fuel oxidation with solids forming, causing filtering problems. Refer to topic, Cold Weather Operation, for additional information.Sulfur
The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid. These acids chemically attack metal surfaces and cause corrosive wear.Certain additives used in lubricating oils contain alkaline compounds that are formulated to neutralize these acids. The measure of this reserve alkalinity in a lubricating oil is known as its Total Base Number (TBN). TBN values are essential to neutralize the acids from combustion gases and to minimize corrosive wear.Fuels containing 0.5% total weight or LESS sulfur may be used with recommended crankcase oil drain intervals using API CF-4 performance oils. With sulfur ABOVE the 0.5% level, use API CF-4 performance oils with an ASTM D2896 Total Base Number (TBN) of 10 times the fuel sulfur for DI engines and 20 times for PC engines for normal oil drain intervals. ASTM Specs can normally be found at your local technological society, library or college.Caterpillar recommends infrared analysis (in conjunction with wear metal analysis) of used oil in determining the effectiveness of oil TBN and acid neutralization. The Caterpillar dealer S O S program provides this information. Regular oil analysis (S O S) will provide information to monitor oil properties and engine wear metals to maintain successful engine protection and establish oil drain intervals.Periodically request fuel sulfur content information from your fuel supplier. Fuel sulfur content can change with each bulk delivery. American Petroleum Institute (API) classification performance oils should have sufficient TBN for fuels with less than 0.5% sulfur. Fuels containing 0.5% or less sulfur may be used with recommended crankcase oil drain intervals using API CF-4 performance oils.Additives
Fuel additives are generally not recommended nor needed for the specified fuels listed. Cetane improvers can be used as necessary for the direct injection engine requirements. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for entrained water may also be necessary.Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used. Other fuel types may be used when economics or fuel availability dictate. Consult your Caterpillar dealer for more information and advice on any specific fuel.For more information
Use only fuel as recommended in this section. The fuels recommended for use in Caterpillar engines are No.2-D diesel fuel and No.2-D fuel oil. No.2-D is preferred, although No.1 grades are acceptable. The following fuel specifications meet Caterpillar requirements. These fuel characteristics should be considered when procuring fuel for use in Caterpillar diesel engines. Caterpillar Diesel Engines are capable of burning a wide range of distillate fuels. The use of clean, stable blends of distillate fuel which meet the following requirements will provide quality engine service life. Filterability
Clean fuels should have no more than 0.1% of sediment and water. Storage of fuel for extended periods of time can cause fuel oxidation with solids forming, causing filtering problems. Refer to topic, Cold Weather Operation, for additional information.Sulfur
The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid. These acids chemically attack metal surfaces and cause corrosive wear.Certain additives used in lubricating oils contain alkaline compounds that are formulated to neutralize these acids. The measure of this reserve alkalinity in a lubricating oil is known as its Total Base Number (TBN). TBN values are essential to neutralize the acids from combustion gases and to minimize corrosive wear.Fuels containing 0.5% total weight or LESS sulfur may be used with recommended crankcase oil drain intervals using API CF-4 performance oils. With sulfur ABOVE the 0.5% level, use API CF-4 performance oils with an ASTM D2896 Total Base Number (TBN) of 10 times the fuel sulfur for DI engines and 20 times for PC engines for normal oil drain intervals. ASTM Specs can normally be found at your local technological society, library or college.Caterpillar recommends infrared analysis (in conjunction with wear metal analysis) of used oil in determining the effectiveness of oil TBN and acid neutralization. The Caterpillar dealer S O S program provides this information. Regular oil analysis (S O S) will provide information to monitor oil properties and engine wear metals to maintain successful engine protection and establish oil drain intervals.Periodically request fuel sulfur content information from your fuel supplier. Fuel sulfur content can change with each bulk delivery. American Petroleum Institute (API) classification performance oils should have sufficient TBN for fuels with less than 0.5% sulfur. Fuels containing 0.5% or less sulfur may be used with recommended crankcase oil drain intervals using API CF-4 performance oils.Additives
Fuel additives are generally not recommended nor needed for the specified fuels listed. Cetane improvers can be used as necessary for the direct injection engine requirements. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for entrained water may also be necessary.Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used. Other fuel types may be used when economics or fuel availability dictate. Consult your Caterpillar dealer for more information and advice on any specific fuel.For more information