Information injection-pump assembly
BOSCH
F 01G 09U 032
f01g09u032
ZEXEL
101601-5990
1016015990
HINO
220204060A
220204060a
Rating:
Service parts 101601-5990 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2133A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101601-5990
as INJECTION-PUMP ASSEMBLY
Include in #2:
104137-4031
as _
Cross reference number
BOSCH
F 01G 09U 032
f01g09u032
ZEXEL
101601-5990
1016015990
HINO
220204060A
220204060a
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.7
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
102.9
100.9
104.9
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
109
101
117
Fixing the lever
*
Remarks
After setting SM.. rack limit
After setting SM.. rack limit
Timer adjustment
Pump speed
r/min
1100--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1050
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)SMA RACK LIMIT; RAL
(3)Set idle sub-spring
(4)Main spring setting
(5)Perform governor adjustment at an ambient temperature of at least 15 deg C (rack limit spring is shape memory alloy).
----------
K=14 RAL=10.4+0.2mm
----------
----------
K=14 RAL=10.4+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=17deg+-5deg b=19deg+-5deg
----------
----------
a=17deg+-5deg b=19deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At delivery
(2)Rack position aa or less, pump speed bb
(3)Contacts normal side pin
(4)Clearance from the pin on the normal side: cc
----------
aa=5.1mm bb=0r/min cc=2.5+-0.5mm
----------
a=53deg+-5deg b=51deg+-5deg c=(6deg)
----------
aa=5.1mm bb=0r/min cc=2.5+-0.5mm
----------
a=53deg+-5deg b=51deg+-5deg c=(6deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Crankcase Breather
Clean
1. Loosen breather retaining clamp (1) on breather.2. Loosen hose clamp (2) and remove breather assembly.3. Wash breather in clean, nonflammable solvent and allow to dry.4. Install new seal.5. Assemble breather and install in reverse order of removal.6. Tighten all hose clamps (2) to 27 4.5 lb in (3.0 0.5 N m). If the crankcase breather is not maintained on a regular basis, it will become plugged. A plugged crankcase breather would result in excessive crankcase pressure that may cause crankshaft seal leakage.Refer to the Torque Specifications section of this manual for Torque for Standard Hose Clamps-Worm Drive Band Type hose clamps for more information.Alternator, Fan And Accessory Drive Belts
Inspect
Inspect the drive belts for wear and replace if they show any signs of wear.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both. 1. Inspect the condition and adjustment of alternator belts and fan drive belts.2. To check the belt tension, apply 25 lbs (110 N) of force midway between the pulleys. Correctly adjusted belts will deflect 1/2 to 3/4 inch (13 to 19 mm).Adjust Alternator Belts
1. To adjust the alternator drive belts, loosen mounting bolt(s) (1) and adjusting bracket nut(s) (2).2. Adjust the alternator in or out by either tightening or loosening adjusting nut(s) (2), as required, to obtain the correct adjustment.3. Tighten bolts (1) and nuts(2).4. If new belts are installed, check belt adjustment again after 30 minutes of engine operation. Replace belts in matched sets only. If only one belt of a matched set is replaced, it will carry more of a load than the belts not replaced since the older belts are stretched. The additional load on the new belt could cause it to break.Adjust Fan Drive Belts
5. To adjust the fan drive belts, loosen mounting bolts and adjust with adjusting bolt.6. Move the fan drive up or down as required to obtain the correct adjustment. Tighten mounting bolts.7. If new belts are installed, check belt adjustment again after 30 minutes of engine operation.Refer to the Service Manual for 3406B Truck Engines for more information or see your Caterpillar dealer.Hoses and Clamps
Inspect/Replace
Hose replacement prior to failure is a cost effective preventive maintenance practice. Replacing a hose before it fails saves money and reduces the chances for unscheduled downtime. By replacing a hose that is cracked, soft or leaking, you will avoid major repairs that could result in a severe engine overheating problem.Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are
Clean
1. Loosen breather retaining clamp (1) on breather.2. Loosen hose clamp (2) and remove breather assembly.3. Wash breather in clean, nonflammable solvent and allow to dry.4. Install new seal.5. Assemble breather and install in reverse order of removal.6. Tighten all hose clamps (2) to 27 4.5 lb in (3.0 0.5 N m). If the crankcase breather is not maintained on a regular basis, it will become plugged. A plugged crankcase breather would result in excessive crankcase pressure that may cause crankshaft seal leakage.Refer to the Torque Specifications section of this manual for Torque for Standard Hose Clamps-Worm Drive Band Type hose clamps for more information.Alternator, Fan And Accessory Drive Belts
Inspect
Inspect the drive belts for wear and replace if they show any signs of wear.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both. 1. Inspect the condition and adjustment of alternator belts and fan drive belts.2. To check the belt tension, apply 25 lbs (110 N) of force midway between the pulleys. Correctly adjusted belts will deflect 1/2 to 3/4 inch (13 to 19 mm).Adjust Alternator Belts
1. To adjust the alternator drive belts, loosen mounting bolt(s) (1) and adjusting bracket nut(s) (2).2. Adjust the alternator in or out by either tightening or loosening adjusting nut(s) (2), as required, to obtain the correct adjustment.3. Tighten bolts (1) and nuts(2).4. If new belts are installed, check belt adjustment again after 30 minutes of engine operation. Replace belts in matched sets only. If only one belt of a matched set is replaced, it will carry more of a load than the belts not replaced since the older belts are stretched. The additional load on the new belt could cause it to break.Adjust Fan Drive Belts
5. To adjust the fan drive belts, loosen mounting bolts and adjust with adjusting bolt.6. Move the fan drive up or down as required to obtain the correct adjustment. Tighten mounting bolts.7. If new belts are installed, check belt adjustment again after 30 minutes of engine operation.Refer to the Service Manual for 3406B Truck Engines for more information or see your Caterpillar dealer.Hoses and Clamps
Inspect/Replace
Hose replacement prior to failure is a cost effective preventive maintenance practice. Replacing a hose before it fails saves money and reduces the chances for unscheduled downtime. By replacing a hose that is cracked, soft or leaking, you will avoid major repairs that could result in a severe engine overheating problem.Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are