Information injection-pump assembly
BOSCH
F 01G 09U 057
f01g09u057
ZEXEL
101607-1300
1016071300
Rating:
Service parts 101607-1300 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101607-1300
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6608
as _
Cross reference number
BOSCH
F 01G 09U 057
f01g09u057
ZEXEL
101607-1300
1016071300
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
131424-5520
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.2
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
57.7
56
59.4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
13.7
11.6
15.8
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.2)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
57.7
56.7
58.7
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
72.6
68.6
76.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
59.7
55.7
63.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+1.25
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
57.1
53.1
61.1
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
130
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=F21
----------
----------
T1=F21
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=10deg+-5deg b=41deg+-3deg
----------
----------
a=10deg+-5deg b=41deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed = cc. Rack position = actual (non-injection rack position).
(3)Rack position = approximately dd
(4)Free (at shipping)
(5)Use the hole above R = ee
----------
aa=1550r/min bb=7-0.5mm cc=275r/min dd=15mm ee=40mm
----------
a=38.5deg+-5deg b=(27deg) c=15deg+-3deg
----------
aa=1550r/min bb=7-0.5mm cc=275r/min dd=15mm ee=40mm
----------
a=38.5deg+-5deg b=(27deg) c=15deg+-3deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(0deg)
----------
aa=13deg
----------
a=(0deg)
Information:
20Oct2015
U-557
A-401
D-483
O-483
TM-15
TA-4
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 20R-0476 INJECTOR ASSEMBLIES FROM DEALER PARTS STOCK
7750 PI70592
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31Jan2016
PROBLEM
All 20R-0476 Injector Assemblies in dealer parts stock need to be inspected for the date code. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock. These injector as may have a nozzle assembly marked 2645K015 which is not correct. (Image1 = Incorrect) The correct nozzle assembly should be marked 2645K016. (Image2 = Correct) These two nozzles are not interchangeable.
ACTION REQUIRED
Inspect the date code on all 20R-0476 Injector Assemblies in dealer parts stock. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.