101403-9041 ZEXEL F 01G 09U 01F BOSCH INJECTION-PUMP ASSEMBLY f01g09u01f 1014039041


 

Information injection-pump assembly

BOSCH F 01G 09U 01F f01g09u01f
ZEXEL 101403-9041 1014039041
101403-9041 INJECTION-PUMP ASSEMBLY
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Service parts 101403-9041 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9430
3. GOVERNOR 105921-9851
4. SUPPLY PUMP 105220-7060
5. AUTOM. ADVANCE MECHANIS 105671-0610
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6620
11. Nozzle and Holder 16600-19D20
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-4270
14. NOZZLE 105017-2440
15. NOZZLE SET

Include in #1:

101403-9041 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 01F f01g09u01f
ZEXEL 101403-9041 1014039041


Zexel num
Bosch num
Firm num
Name
101403-9041 
101403-9042 
F 01G 09U 01F 
   
INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions
Test oil
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
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.2 3.15 3.25
Rack position
Point A
  R=A
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
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
 
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
 

Test data Ex:

Governor adjustment

Test data 101403-9041
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
----------

Speed control lever angle

Test data 101403-9041
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

Stop lever angle

Test data 101403-9041
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=15mm
----------
a=10deg+-5deg b=29deg+-5deg

Timing setting

Test data 101403-9041
(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)




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

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