101403-9190 ZEXEL 9 400 611 248 BOSCH INJECTION-PUMP ASSEMBLY 9400611248 1014039190


 

Information injection-pump assembly

BOSCH 9 400 611 248 9400611248
ZEXEL 101403-9190 1014039190
101403-9190 INJECTION-PUMP ASSEMBLY
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Service parts 101403-9190 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9330
3. GOVERNOR 105922-0110
4. SUPPLY PUMP 105220-7060
5. AUTOM. ADVANCE MECHANIS 105671-0630
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6170
11. Nozzle and Holder 16600-17D02
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-3691
14. NOZZLE 105017-2010
15. NOZZLE SET

Include in #1:

101403-9190 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 248 9400611248
ZEXEL 101403-9190 1014039190


Zexel num
Bosch num
Firm num
Name
101403-9190 
101403-9191 
9 400 611 248 
   
INJECTION-PUMP ASSEMBLY
FD46T * 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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   13.6
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   93.5 91.9 95.1
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.   12 10.2 13.8
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(13.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   93.5 92.5 94.5
Basic   *
Fixing the lever   *
Boost pressure kPa   69.3 69.3
Boost pressure mmHg   520 520
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.55
Pump speed r/min   1550 1550 1550
Average injection quantity mm3/st.   96.5 92.5 100.5
Fixing the lever   *
Boost pressure kPa   69.3 69.3
Boost pressure mmHg   520 520
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-1.15
Boost pressure kPa   18.7 17.4 20
Boost pressure mmHg   140 130 150
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2(R1-0. 15)
Boost pressure kPa   56 56 56
Boost pressure mmHg   420 420 420
Timer adjustment
Pump speed r/min   1200--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1490
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101403-9190
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=P15 BCL=1.15+-0.1mm
----------

Speed control lever angle

Test data 101403-9190
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101403-9190
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 101403-9190
(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=12deg
----------
a=(50deg)




Information:


Do not engage starter when flywheel is turning.Do not start engine under load.
Above 0°C (32°F)
1. Place the transmission or other power takeoff attachments in NEUTRAL. For air start systems; check the air supply before starting the engine. There must be 690 kPa (100 psi) air pressure available.2. Move governor control lever (throttle) or depress the accelerator to half engine speed position.3. Turn the battery disconnect switch (if equipped) to the ON position. 4. Push the air start knob (1) IN, or ... ... turn the start switch (2) for marine, industrial and generator set engines or ... ... turn the start switch (3) for machines (vehicles) to the START position.
Do not crank the engine for more than 30 seconds. Allow 2 minutes for the starter to cool before cranking again. If oil pressure does not rise within 15 seconds after the engine starts, stop the engine and make necessary corrections.
5. Release the start switch or air start knob when the engine starts.6. Do not apply load to the engine or increase engine speed until oil pressure and all temperature gauges reach operating temperature. Check all gauges during the warm-up period.Below 0°C (32°F)
Ether is poisonous and flammable.Do not store replacement cylinders in living areas or in the operator's compartment.Do not smoke while changing ether cylinders.Use ether only in well ventilated areas.Use it with care to avoid fires.Avoid breathing of the vapors or repeated contact of ether with skin.Do not puncture or burn cylinders.Discard cylinders in a safe place.Keep ether container away from heat, sparks, open flame, or open sunlight. It may explode.Do not store replacement cylinders at temperatures above 49°C (120°F).Do not use cylinders in environments above 93°C (200°F).
1. Depress ether switch and hold for 3 seconds, then release. For air start system; check the air supply before starting the engine. There must be 690 kPa (100 psi) air pressure available.2. Push the air start knob IN or turn the start switch for engines, or turn the start switch for machines (vehicles) to the START position.3. Begin cranking the engine, and depress ether switch and hold for 3 seconds then release. Additional injections of ether may be required to start and/or achieve low idle speed.4. Operate the engine at low speed and/or load until all systems reach operating temperatures. Check all gauges during the warmup period.
Do not use excessive starting fluid during starting or after the engine is running. Do not crank the engine for more than 30 seconds. Allow 2 minutes for the starter motor to cool before cranking again.If oil pressure does not rise within 15 seconds after the engine starts, stop the engine and make necessary corrections.
Turn the battery disconnect switch (if equipped) OFF after the engine is stopped to prevent battery discharge while starter motor is cooling.For starting below -18°C (0°F), use of optional cold weather starting aids are recommended. A coolant heater or extra battery capacity may be required.For temperatures below -23°C (-10°F), consult your Caterpillar dealer or refer to the "Cold Weather Operation

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