Information injection-pump assembly
BOSCH
F 01G 09U 0BG
f01g09u0bg
ZEXEL
106873-7621
1068737621
Rating:
Service parts 106873-7621 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME161933
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/24.5{250}
14.
NOZZLE
Include in #1:
106873-7621
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0BG
f01g09u0bg
ZEXEL
106873-7621
1068737621
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.7
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
144
139.7
148.3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
445
445
445
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.7)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
144
143
145
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
135
143
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.
139.5
135.5
143.5
Fixing the lever
*
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)Damper spring setting
----------
T1=AD95
----------
----------
T1=AD95
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=30deg+-5deg b=34deg+-3deg
----------
aa=37.5mm
----------
a=30deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)At pump speed bb and rack position cc, set the stopper bolt. (Confirm non-injection.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(12.7)+0.8mm
----------
----------
N1=1100r/min Ra=R1(12.7)+0.8mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=6deg
----------
a=(50deg)
----------
aa=6deg
----------
a=(50deg)
Information:
4. Install a new seal washer (6).Use 6V-4979 Carbon Stop Seal Tool (4) to install new carbon dam (5) on nozzle (2).7000 Series Nozzles
The part number for compression seal (3) is not the same for all nozzles. If the correct seal is not installed, the result will be high emissions. This is NOT acceptable.
Troubleshooting (Pencil-Type Fuel Nozzles Only)
A. To troubleshoot these nozzles, refer to the Troubleshooting Guide For Pencil-Type Fuel Nozzles located in this manual.B. Refer to Special Instruction SEHS8627 "Use of 8S-2245 Nozzle Cleaning Tool Group" for the correct procedure (according to the part number of the nozzle) in order to clean these nozzles. C. If VO is LESS than the specified value for a specific part number, DO NOT use the nozzle.Troubleshooting Guide For Pencil-Type Fuel Nozzles
Troubleshooting Guide For Caterpillar 7000 Series Direct Injection Fuel Nozzles
Engine Nozzle Test Record Form (Sample Copy)
Repair/Calibration Information For 5P-4150 Tester Group
For the repair and/or calibration of the 5P-4150 Tester Group, contact the manufacturer: U.S. Mail:OTC Division
SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060, U.S.A.
Telephone:(507) 455-7000(800) 533-6127 Fax:(800) 955-8329Test Equipment Calibration
Caterpillar fuel nozzle and unit injector testers feature premium quality, liquid filled gauges for high accuracy and durability.Pressure gauges, in this application must be of high quality in order to provide accurate and consistent test results.To maintain this high degree of accuracy, gauge calibration should be checked at a MINIMUM of once a year. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester". However, calibration should be checked at any time when the test results have become INCONSISTENT or if the gauge needle does NOT return to the 0 (zero) range when the test pressure is relieved.Calibration
Two methods are available for gauge calibration:* Method 1: Calibration by gauge manufacturer.* Method 2: 5P-8558 Pressure Gauge Calibrating Group. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester".Calibration By Gauge Manufacturer (Method 1)
Certified calibration services are offered by Carrier - Oehler Company, a Caterpillar certified supplier of premium quality gauges.The Carrier - Oehler Company can promptly check and recalibrate gauges at a low cost.The Carrier - Oehler Company will also repair and recalibrate damaged gauges at a fraction of the cost of a new gauge.When sending gauges to Carrier - Oehler Company, include the following information:* Person or department that gauges and/or correspondence is to be directed to.* List the quantity and a brief description of the gauge(s) problem or the service requested.* Dealer name and address.* Telephone number.* Fax number. The Carrier - Oehler Company will advise you if repair costs exceed 50 percent of a new gauge. Questions on costs, service, and repair time should be directed to the Caterpillar Repair Desk:(800) 321-3241 Shipping:Carrier - Oehler Company
16965 Vincennes Avenue
South Holland, Illinois 60473
U.S. Mail:Carrier - Oehler Company
Post Office Box 40
16965 Vincennes Avenue
South Holland, Illinois 60473
Telephone:(708) 339-8200 Fax:(708) 339-98305P-8558 Pressure Gauge Calibrating Group (Method 2)
(1) 5P-0946 Box Assembly.(2) 1P-2375 Quick
The part number for compression seal (3) is not the same for all nozzles. If the correct seal is not installed, the result will be high emissions. This is NOT acceptable.
Troubleshooting (Pencil-Type Fuel Nozzles Only)
A. To troubleshoot these nozzles, refer to the Troubleshooting Guide For Pencil-Type Fuel Nozzles located in this manual.B. Refer to Special Instruction SEHS8627 "Use of 8S-2245 Nozzle Cleaning Tool Group" for the correct procedure (according to the part number of the nozzle) in order to clean these nozzles. C. If VO is LESS than the specified value for a specific part number, DO NOT use the nozzle.Troubleshooting Guide For Pencil-Type Fuel Nozzles
Troubleshooting Guide For Caterpillar 7000 Series Direct Injection Fuel Nozzles
Engine Nozzle Test Record Form (Sample Copy)
Repair/Calibration Information For 5P-4150 Tester Group
For the repair and/or calibration of the 5P-4150 Tester Group, contact the manufacturer: U.S. Mail:OTC Division
SPX Corporation
655 Eisenhower Drive
Owatonna, Minnesota 55060, U.S.A.
Telephone:(507) 455-7000(800) 533-6127 Fax:(800) 955-8329Test Equipment Calibration
Caterpillar fuel nozzle and unit injector testers feature premium quality, liquid filled gauges for high accuracy and durability.Pressure gauges, in this application must be of high quality in order to provide accurate and consistent test results.To maintain this high degree of accuracy, gauge calibration should be checked at a MINIMUM of once a year. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester". However, calibration should be checked at any time when the test results have become INCONSISTENT or if the gauge needle does NOT return to the 0 (zero) range when the test pressure is relieved.Calibration
Two methods are available for gauge calibration:* Method 1: Calibration by gauge manufacturer.* Method 2: 5P-8558 Pressure Gauge Calibrating Group. Additional information can be found in NEHS0631 "General Maintenance And Troubleshooting For Fuel Injection Equipment Test Stands (FIETS) And 5P-4150 Nozzle Tester".Calibration By Gauge Manufacturer (Method 1)
Certified calibration services are offered by Carrier - Oehler Company, a Caterpillar certified supplier of premium quality gauges.The Carrier - Oehler Company can promptly check and recalibrate gauges at a low cost.The Carrier - Oehler Company will also repair and recalibrate damaged gauges at a fraction of the cost of a new gauge.When sending gauges to Carrier - Oehler Company, include the following information:* Person or department that gauges and/or correspondence is to be directed to.* List the quantity and a brief description of the gauge(s) problem or the service requested.* Dealer name and address.* Telephone number.* Fax number. The Carrier - Oehler Company will advise you if repair costs exceed 50 percent of a new gauge. Questions on costs, service, and repair time should be directed to the Caterpillar Repair Desk:(800) 321-3241 Shipping:Carrier - Oehler Company
16965 Vincennes Avenue
South Holland, Illinois 60473
U.S. Mail:Carrier - Oehler Company
Post Office Box 40
16965 Vincennes Avenue
South Holland, Illinois 60473
Telephone:(708) 339-8200 Fax:(708) 339-98305P-8558 Pressure Gauge Calibrating Group (Method 2)
(1) 5P-0946 Box Assembly.(2) 1P-2375 Quick