Information injection-pump assembly
BOSCH
F 01G 09U 04A
f01g09u04a
ZEXEL
101605-9020
1016059020
NISSAN-DIESEL
16700L9201
16700l9201

Rating:
Service parts 101605-9020 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-L9200
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101605-9020
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1970
as _
Cross reference number
BOSCH
F 01G 09U 04A
f01g09u04a
ZEXEL
101605-9020
1016059020
NISSAN-DIESEL
16700L9201
16700l9201
Zexel num
Bosch num
Firm num
Name
101605-9020
F 01G 09U 04A
16700L9201 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FD6 * K 14BE PE6A PE
FD6 * K 14BE PE6A PE
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-4-2-6-
3-5
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.1
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
48.7
47.1
50.3
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
-
Rack position
9.8+-0.5
Pump speed
r/min
335
335
335
Average injection quantity
mm3/st.
8
6.2
9.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
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
A
Rack position
R1(10.1)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
48.7
47.7
49.7
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
62
62
72
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
----------
T1=G11
----------
----------
T1=G11
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=17deg+-5deg b=34.5deg+-3deg
----------
aa=39mm
----------
a=17deg+-5deg b=34.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
a=20deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR

V1:Supply voltage
Vf:Full side output voltage
Vi:Idle side output voltage
(a) Speed lever
(B) Link
(c) Nut
(F) Full
(I) Idle
(P) Potentiometer
1. Load sensor adjustment
(1)Apply DC5 = V1 voltage between potentiometer connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2).
(2)Move the speed lever (A) until it contacts the full side stopper bolt and then turn the link (B) to adjust the potentiometer (P)'s output voltage to Vf.
(3)Confirm that the speed lever (A) turns smoothly between idle (I) and Full (F) and tighten the nut (C). (Tightening torque: 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m})
(4)Move the speed lever (A) several times between idle (I) and full (F) and confirm that the voltage is Vf when it contacts the full side stopper bolt and Vi when it contacts the idle side stopper bolt.
----------
V1=5+-0.02V Vf=3.75+-0.2V Vi=0+0.5V
----------
----------
V1=5+-0.02V Vf=3.75+-0.2V Vi=0+0.5V
----------
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'P' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18.5deg
----------
a=(60deg)
----------
aa=18.5deg
----------
a=(60deg)
Information:
The combustion process of a diesel engine produces exhaust products such as smoke (visible), hydrocarbons and oxides of nitrogen (invisible). The dark smoke emitted by a diesel engine is soot or carbon particles and even in low concentration make the diesel exhaust highly visible and offensive to most people. Every effort must be made to eliminate smoke even though it can be considered more of a nuisance than a pollutant.Under certain conditions oxides of nitrogen react with certain hydrocarbons to form smog which can become irritating and toxic if large concentrations accumulate. Concentrations of this pollutant combined with pollution of other sources all contribute to the total air quality problem.As an engine manufacturer, our goal is to see that environmental standards are met with a minimum additional complexity or cost to the product. Throughout the years, continuing research and design improvements have been directed at minimizing exhaust emissions. Caterpillar has incorporated items such as -TURBOCHARGING: Reduces exhaust noise and provides more air per cylinder allowing the fuel to burn more efficiently. These engines are integrally designed for turbocharging.AIR-FUEL RATIO CONTROL FOR TURBOCHARGED ENGINES: Limits the amount of fuel during acceleration to minimize smoke levels.RECOMMEND FUELS, LUBRICATING OILS AND MAINTENANCE SCHEDULES: To assure minimum exhaust emissions.Maintenance Recommendations
Caterpillar Truck Engines are certified by the United States Environmental Protection Agency to comply with smoke emission standard limits prescribed by Federal laws at the time of manufacture.Efficiency of emission control and good engine performance depend on adherence to proper operation and maintenance recommendations, use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be entrusted to your authorized dealer.Various chemical fuel additives are commercially available that claim to reduce visible smoke. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require the certification of engines without a smoke depressant.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the user that the use of such parts will not adversely affect emission levels.Regular service intervals along with special emphasis on the following items are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the Lubrication and Maintenance Section of this Operation Guide for details and maintenance schedule. If the engine is operating under severe conditions, adjust maintenance schedule accordingly. See your authorized dealer to help analyze your specific maintenance schedule.The following explanation of required emission related component maintenance has been keyed by number to correspond with item number in the maintenance chart.1. COOLANT - LEVEL AND PROTECTION: Check the engine coolant level daily with the engine stopped and cool. Release cooling system pressure before checking. Fill to proper level with permanent-type antifreeze and water as free as possible from scale forming minerals. DO NOT USE
Caterpillar Truck Engines are certified by the United States Environmental Protection Agency to comply with smoke emission standard limits prescribed by Federal laws at the time of manufacture.Efficiency of emission control and good engine performance depend on adherence to proper operation and maintenance recommendations, use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be entrusted to your authorized dealer.Various chemical fuel additives are commercially available that claim to reduce visible smoke. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require the certification of engines without a smoke depressant.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the user that the use of such parts will not adversely affect emission levels.Regular service intervals along with special emphasis on the following items are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the Lubrication and Maintenance Section of this Operation Guide for details and maintenance schedule. If the engine is operating under severe conditions, adjust maintenance schedule accordingly. See your authorized dealer to help analyze your specific maintenance schedule.The following explanation of required emission related component maintenance has been keyed by number to correspond with item number in the maintenance chart.1. COOLANT - LEVEL AND PROTECTION: Check the engine coolant level daily with the engine stopped and cool. Release cooling system pressure before checking. Fill to proper level with permanent-type antifreeze and water as free as possible from scale forming minerals. DO NOT USE
Have questions with 101605-9020?
Group cross 101605-9020 ZEXEL
Daewoo
Nissan-Diesel
101605-9020
F 01G 09U 04A
16700L9201
INJECTION-PUMP ASSEMBLY
FD6
FD6