101601-7490 ZEXEL 9 400 614 658 BOSCH INJECTION-PUMP ASSEMBLY 9400614658 1016017490 1156009463


 

Information injection-pump assembly

BOSCH 9 400 614 658 9400614658
ZEXEL 101601-7490 1016017490
ISUZU 1156009463 1156009463
101601-7490 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 614 658 9400614658
ZEXEL 101601-7490 1016017490
ISUZU 1156009463 1156009463


Zexel num
Bosch num
Firm num
Name
101601-7490 
101601-8150 
9 400 614 658 
1156009463  ISUZU
INJECTION-PUMP ASSEMBLY
6QA1 * K 14BF PE6AD PE

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   131424-0220
Overflow valve opening pressure kPa   147 113 181
Overflow valve opening pressure kgf/cm2   1.5 1.15 1.85
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   10.9
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   106.2 104.2 108.2
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   11.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   108.1 107.1 109.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   8.6+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   11.5 9.2 13.8
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   -
Pump speed r/min   150 150 150
Each cylinder's injection qty mm3/st.   140 140
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   500
Advance angle deg.   0.3
Timer adjustment_02
Pump speed r/min   600
Advance angle deg.   0.8 0.1 0.8
Timer adjustment_03
Pump speed r/min   700
Advance angle deg.   0.8 0.3 1.3
Timer adjustment_04
Pump speed r/min   900
Advance angle deg.   2 1.5 2.5
Timer adjustment_05
Pump speed r/min   1150
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7490
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=6.5+-0.5mm SXL=12.1+-0.1mm
----------

Speed control lever angle

Test data 101601-7490
F:Full speed (1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=1150r/min bb=550r/min
----------
a=3deg+-5deg b=8deg+-5deg

0000000901

Test data 101601-7490
F:Full load I:Idle (1)Stopper bolt setting (2)Attach the return spring to the upper hole and adjust.
----------

----------
a=4deg+-5deg b=21deg+-3deg

Stop lever angle

Test data 101601-7490
N:Pump normal S:Stop the pump.
----------

----------
a=35.5deg+-5deg b=71deg+-5deg




Information:

Torque for Standard Bolts, Nuts and Taperlock Studs
The following charts give general torques for bolts, nuts, and taperlock studs. For torque specifications not included in this section, refer to SENR3130, Torque Specifications, available from your Caterpillar dealer.
Torques for Bolts and Nuts With Standard Threads
Torques for Taperlock Studs
Use these standard torque values for all fasteners, unless otherwise specified in this manual or in the Service Manual.Torque for Metric Fasteners
Be very careful never to mix metric with customary (SAE standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.
Material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torque values for bolts and nuts. Use these standard torque values unless otherwise specified in this publication. Metric hardware must be replaced with metric hardware. Check Parts Manual for proper replacement.Torques for Bolts and Nuts with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose. Torque for Constant Torque Hose Clamps
Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new constant torque hose clamp will help prevent these failures. A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp.
Installation
Each installation application can be different depending on the type of hose, fitting material, and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).

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