Information injection-pump assembly
BOSCH
9 400 619 919
9400619919
ZEXEL
106891-1571
1068911571
ISUZU
1156032081
1156032081

Rating:
Service parts 106891-1571 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106891-1571
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 919
9400619919
ZEXEL
106891-1571
1068911571
ISUZU
1156032081
1156032081
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4320
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-7-3-
6-5-4-2
Pre-stroke
mm
4.2
4.17
4.23
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
7.8
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
101
99.5
102.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.8
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
100
96
104
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
4.7+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
F
Rack position
-
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
3
Fixing the lever
*
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Damper spring setting: DL
(5)Variable speed specification: idling adjustment
(6)Main spring setting
----------
RT=0.8 TH=1.7mm DL=3.7-0.2mm
----------
----------
RT=0.8 TH=1.7mm DL=3.7-0.2mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=150mm
----------
a=5deg+-5deg b=(15deg)+-5deg
----------
aa=150mm
----------
a=5deg+-5deg b=(15deg)+-5deg
0000000901

F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Drive side
----------
aa=23.5mm
----------
a=73deg+-5deg b=40deg+-5deg
----------
aa=23.5mm
----------
a=73deg+-5deg b=40deg+-5deg
0000001201

(1)Variable speed specification
(2)Minimum - maximum speed specification
(3)Use the hole at R = aa
----------
aa=130mm
----------
a=13deg+-5deg b=(20deg)
----------
aa=130mm
----------
a=13deg+-5deg b=(20deg)
0000001501 LEVER

2-stage changeover lever adjustment
(A) Speed lever
(B) Load lever
(C) 2-stage changeover lever
(D) Link
(E) Bolt
1. Minimum-maximum speed specification adjustment (when running)
(1)After completing governor adjustment, hold the 2-stage changeover lever (C) so that the speed lever (A) contacts the full speed stopper.
(2)In this condition, the load lever is held in the idle position.
(3)Adjust bolt (E) so that the clearance between the pin underneath lever (C) and the end of the long groove in link (D) is L.
(4)Lock using the nut.
2. Variable speed specification adjustment (at operation)
(1)Hold the 2-stage changeover lever (C) so that the load lever (B) contacts the full load stopper. (When the load lever is equipped with a cancel mechanism, move it so that it contacts the stopper without canceling.)
(2)In this condition, confirm that the speed lever (A) moves from idle to full speed.
----------
L=1~2mm
----------
----------
L=1~2mm
----------
0000001601 ACS

(A) Set screw
1. Aneroid compensator unit adjustment
Screw in (A) to obtain L1.
2. Adjustment following governor installation
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in the aneroid compensator to obtain the performance shown in the graph above.
----------
N1=1150r/min L1=(0.1~0.5)mm
----------
R1=7.8mm R2=7.1mm P1=(89.8)kPa((674)mmHg) P2=69.8+-0.7kPa(524+-5 mmHg) Q1=120.5+-4cm3/1000st Q2=104+-10cm3/1000st
----------
N1=1150r/min L1=(0.1~0.5)mm
----------
R1=7.8mm R2=7.1mm P1=(89.8)kPa((674)mmHg) P2=69.8+-0.7kPa(524+-5 mmHg) Q1=120.5+-4cm3/1000st Q2=104+-10cm3/1000st
Timing setting

(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(170deg)
----------
aa=12deg
----------
a=(170deg)
Information:
Caterpillar does not recommend checking actual engine bearing clearances, particularly on small engines, because of the possibility of obtaining inaccurate results, and the possibility of damaging the bearing or journal surfaces. Each Caterpillar engine is quality checked for specific wall thickness.
If the crankshaft journals and bores for the cylinder block and connecting rods were measured at disassembly and found to be within specification, no further checks are necessary when using the correct bearing. However, if the serviceman still wants to measure the bearing clearances, Plastigage is an acceptable method. Plastigage is less accurate on small diameter journals where clearances are less than 0.10 mm (0.004 in).
Use of lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
1. The serviceman must be very careful to use Plastigage correctly. The following points must be remembered: a. Be sure that the backs of the bearings and the bores are clean and dry.b. The bearing locking tabs must be properly seated in their slots.c. The crankshaft must be free of oil where it is in contact with the Plastigage.d. If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight, and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.e. Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.f. Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench to tighten the baring cap mounting bolts. Be careful not to dislodge the bearing when the cap is installed.g. Do not turn the crankshaft with the Plastigage installed. When using Plastigage to measure bearing clearances, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major width to be sure they are within specification range.h. Carefully remove the bearing cap, but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. See the photograph which illustrates this.i. Remove all Plastigage before reinstalling the bearing cap.