101606-0583 ZEXEL F 01G 09U 1BM BOSCH INJECTION-PUMP ASSEMBLY f01g09u1bm 1016060583 1156035013


 

Information injection-pump assembly

BOSCH F 01G 09U 1BM f01g09u1bm
ZEXEL 101606-0583 1016060583
ISUZU 1156035013 1156035013
101606-0583 INJECTION-PUMP ASSEMBLY
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Service parts 101606-0583 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6851
3. GOVERNOR 105411-2721
4. SUPPLY PUMP 105220-7230
5. AUTOM. ADVANCE MECHANIS 105672-0840
6. COUPLING PLATE 105661-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-8341
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 16.7(170)/19.6(200)
13. NOZZLE-HOLDER 105041-4410
14. NOZZLE
15. NOZZLE SET 105019-2900

Include in #1:

101606-0583 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH F 01G 09U 1BM f01g09u1bm
ZEXEL 101606-0583 1016060583
ISUZU 1156035013 1156035013


Zexel num
Bosch num
Firm num
Name
101606-0583 
101606-0584 
F 01G 09U 1BM 
1156035013  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TRC- * 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   1-5-3-6- 2-4
Pre-stroke mm   4.2 4.15 4.25
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   10.5
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   102 100.5 103.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   109 109
Boost pressure mmHg   820 820
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.5+-0.5
Pump speed r/min   440 440 440
Average injection quantity mm3/st.   12 10.7 13.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   9.3
Boost pressure kPa   36.7 32.7 40.7
Boost pressure mmHg   275 245 305
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   (10.5)
Boost pressure kPa   96 96 96
Boost pressure mmHg   720 720 720
Timer adjustment
Pump speed r/min   1300++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1300.
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   1 1 1
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101606-0583
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
----------
K=11 BCL=(1.2)mm
----------

Speed control lever angle

Test data 101606-0583
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=9deg+-5deg b=23deg+-5deg

Stop lever angle

Test data 101606-0583
N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=53deg+-5deg b=45deg+-5deg

0000001501 TAMPER PROOF

Test data 101606-0583
Tamperproofing-equipped boost compensator cover installation procedure (1)Before adjusting the governor and the boost compensator, temporarily tighten the screw to the specified torque. (Do not damage the thread.) (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=29.4~39.2N-m(3~4kgf-m)
----------

Timing setting

Test data 101606-0583
(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(90deg)




Information:

Emissions Warranty
Caterpillar Inc. warrants to the initial owner and subsequent owner of a diesel truck engines (powering on-highway trucks), that such engine is ...1. Designed, built and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the United States Environmental Protection Agency (EPA).2. Free from defects in materials and workmanship in specific emission related parts for a period of 60 months, 100,000 miles (161 000 km) or 3,000 hours of operation, whichever occurs first, after date of delivery to the initial owner.If an emission related part fails during the warranty period, it will be repaired or replaced. Any such part repaired or replaced under warranty is warranted for the remainder of the warranty period.During the term of this warranty, Caterpillar Inc. will provide through a Caterpillar dealer or other establishment authorized by it, repair or replacement of any warranted part at no change to the truck engine owner.In an emergency, repairs may be performed at any service establishment, or by the owner, using any replacement part.Caterpillar Inc. will reimburse the owner for their expenses, including diagnostic charges for such emergency repair. These expenses shall not exceed Caterpillar Inc. suggested retail price for all warranted parts replaced, and labor charges based on Caterpillar Inc. recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate.As a condition of reimbursement, replaced parts and receipted invoices must be presented at a place of business of a Caterpillar dealer or other establishment authorized by Caterpillar Inc.Limitations & Responsibilities
The warranty is subject to the following:Caterpillar Inc. Responsibilities
During the emission warranty period, if a defect in material or workmanship of an emission related part or component is found, Caterpillar Inc. will provide:* New, Remanufactured or repaired parts and/or components, approved pursuant to EPA Regulations, required to correct the defect. Items replaced under this warranty become the property of Caterpillar Inc.* Reasonable and customary labor, during normal working hours, required to make the warranty repair. This includes labor to remove and install the engine, if necessary.Owner Responsibilities
During the emission warranty period, the owner is responsible for:* Premium or overtime labor costs, unless essential to prevent loss to perishable goods.* Costs to investigate complaints which are not caused by a defect in Caterpillar Inc. material or workmanship.* Providing timely notice of a warrantable failure and promptly making the product available for repair.Limitations
Caterpillar Inc. is not responsible for resultant damages to an emission related part or component resulting from:* Any application or installation Caterpillar Inc. deems improper.* Attachments, accessory items or parts not sold nor approved by Caterpillar Inc.* Improper truck engine maintenance, repair or abuse.* Owner's unreasonable delay in making the product available after being notified of a potential product problem.This warranty is in addition to Caterpillar Inc. standard warranty, applicable to the truck engine product involved.Remedies under this warranty are limited to the provision of material and services as specified herein. Caterpillar Inc. is not responsible for incidental or consequential damages.

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