Information injection-pump assembly
BOSCH
9 400 611 248
9400611248
ZEXEL
101403-9190
1014039190

Rating:
Service parts 101403-9190 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-17D02
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 611 248
9400611248
ZEXEL
101403-9190
1014039190
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
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
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
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=P15 BCL=1.15+-0.1mm
----------
----------
T1=P15 BCL=1.15+-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=40deg+-3deg
----------
aa=32mm
----------
a=71deg+-5deg b=40deg+-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=12deg
----------
a=(50deg)
----------
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