Information injection-pump assembly
BOSCH
F 01G 09U 0BU
f01g09u0bu
ZEXEL
106971-2041
1069712041
MITSUBISHI
ME091684
me091684
Rating:
Service parts 106971-2041 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME091276
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/21.6(220)
15.
NOZZLE SET
Include in #1:
106971-2041
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0BU
f01g09u0bu
ZEXEL
106971-2041
1069712041
MITSUBISHI
ME091684
me091684
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
131424-4620
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
1-2-7-8-
5-6-3-4-
9-10
Pre-stroke
mm
4.8
4.75
4.85
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. 72 71.5 72.5
Cal 1-7 deg. 72 71.5 72.5
Difference between angles 3
Cal 1-8 deg. 117 116.5 117.5
Cal 1-8 deg. 117 116.5 117.5
Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5
Cal 1-5 deg. 144 143.5 144.5
Difference between angles 5
Cal 1-6 deg. 189 188.5 189.5
Cal 1-6 deg. 189 188.5 189.5
Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5
Cal 1-3 deg. 216 215.5 216.5
Difference between angles 7
Cal 1-4 deg. 261 260.5 261.5
Cal 1-4 deg. 261 260.5 261.5
Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5
Cal 1-9 deg. 288 287.5 288.5
Difference between angles 9
Cal 1-10 deg. 333 332.5 333.5
Cal 1-10 deg. 333 332.5 333.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.7
Pump speed
r/min
650
650
650
Each cylinder's injection qty
mm3/st.
130
126.1
133.9
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
17
14.4
19.6
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.7)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
130
129
131
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.7)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
131.5
129.5
133.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
135
175
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
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.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Deliver with positive torque control spring not operating
(3)Supplied with torque spring not set.
(4)Excess fuel setting for starting: SXL
(5)Damper spring setting
----------
SXL=11.4+-0.1mm
----------
----------
SXL=11.4+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=19.5deg+-5deg
----------
----------
a=19.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=27deg+-3deg
----------
----------
a=10deg+-5deg b=27deg+-3deg
Stop lever angle
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Free (at shipping)
----------
aa=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg
----------
aa=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg
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=325r/min Ra=5.7+-0.1mm
----------
----------
N1=325r/min Ra=5.7+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
TERMINATION DATE
31Jan2012
PROBLEM
The existing fuel injection pump can fail on certain CP-533E and CS-533E Vibratory Soil Compactors. If the existing fuel injection pump fails it can cause low power, poor starting, fuel leaks, and engine performance issues.
AFFECTED PRODUCT
Model Identification Number
CP-533E ASM00310-00311, 313, 316-380
BZG00466-01134
TLH00101-00147
CS-533E ASL03060, 3068, 3092, 3103, 3106, 3110, 3121, 3125-3126, 3130-3135, 3138-3872
BZE01120-02370
TBE00148-00237
TJL00100-01472, 1474-1628, 1630-1631, 1633-1637, 1639-1678
PARTS NEEDED
Qty
Part Number Description
1 2845000 PUMP GP-F INJ -B
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Replace the failed fuel injection pump. Refer to the engine's Disassembly and Assembly, "Fuel Injection Pump - Remove and Install".
While carrying out "Fuel Injection Pump - Remove", please ensure that the fuel injection pump gear backlash is removed and the fuel injection pump locking bolt is tightened to a torque of 17 N.m (13 lb ft).
Fuel injection pumps that have not been locked correctly will have the claim rejected or debited.
After the new fuel injection pump has been installed, carry out checks for air in the fuel. Refer to the engine's Testing and Adjusting, "Air in Fuel - Test".
To ensure correct priming of the fuel system on first start-up, follow the procedure below.
1. Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly.
2. Turn the ignition key to the RUN position. Leave the ignition key in the RUN position for three minutes.
3. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
Note: If necessary, loosen the union nuts on the fuel injection lines at the connection with the fuel injector until fuel is evident. Stop cranking the engine. Tighten the union nuts to a torque of 30 N.m (22 lb ft).
4. Start the engine and run the engine at low idle for one minute.
5. Cycle the throttle lever from the low idle position to the high idle position three times. The cycle time for the throttle lever is one second to six seconds for one complete cycle.
6. Check for leaks in the fuel system.
DOCUMENTATION PROCEDURE
Please ensure that when submitting the claim the following documentation is provided. If the requested documentation is not provided, the claim may be rejected or debited.
1. Full details of the customer?s complaint and the symptoms witnessed.
2. Test work and checks carried out to diagnose that the fuel injection pump is the part causing failure.
3. Results from the Testing and Adjusting, "Air in Fuel - Test". Please include photos of any air seen in the SIMS entry.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
PARTS DISPOSITION
***** NACD *****
Hold all failed fuel injection pumps for a Parts Return Request (PRR). A PRR will be issued to you through the