101601-7520 ZEXEL 9 400 619 549 BOSCH INJECTION-PUMP ASSEMBLY 9400619549 1016017520 1156009473


 

Information injection-pump assembly

BOSCH 9 400 619 549 9400619549
ZEXEL 101601-7520 1016017520
ISUZU 1156009473 1156009473
101601-7520 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7520 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4211
3. GOVERNOR 105470-1120
4. SUPPLY PUMP 105210-4271
5. AUTOM. ADVANCE MECHANIS 105644-0021
6. COUPLING PLATE 105662-0630
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4850
11. Nozzle and Holder 1-15300-088-1
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105031-3620
14. NOZZLE 105015-4390
15. NOZZLE SET

Include in #1:

101601-7520 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 549 9400619549
ZEXEL 101601-7520 1016017520
ISUZU 1156009473 1156009473


Zexel num
Bosch num
Firm num
Name
101601-7520 
9 400 619 549 
1156009473  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 101601-7520
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
----------

0000000901

Test data 101601-7520
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 101601-7520
N:Pump normal S:Stop the pump.
----------

----------
a=50.5deg+-5deg b=71deg+-5deg




Information:

ELC cooling systems can withstand contamination of up to ten percent of conventional HD coolant/antifreeze. If the contamination exceeds ten percent of the total system capacity, perform either one of the following two procedures:* Drain the cooling system. Flush the system with clean water. Refill the system with ELC.* Maintain the cooling system as if the system is filled with conventional HD coolant/antifreeze.Commercial Extended Life Coolant
If Caterpillar extended life coolant is not used, select a commercial extended life coolant that meets the Caterpillar EC-1 specification. Do not use a product that is labeled as an extended life coolant but does not meet the Caterpillar EC-1 specification. Follow the coolant maintenance guidelines of the commercial extended life coolant supplier. In all cases, use distilled or deionized water or use water that has the properties listed in the Caterpillar Water Quality Limits chart.Caterpillar Diesel Engine Antifreeze/Coolant (DEAC)
For cooling systems using conventional HD coolant, Caterpillar recommends the use of Caterpillar Diesel Engine Antifreeze/Coolant (DEAC). DEAC is an alkaline type, single-phase, ethylene glycol-based antifreeze/coolant. DEAC contains inorganic corrosion inhibitors and anti-foaming agents.Contact your Caterpillar dealer for part numbers and available container sizes.Caterpillar DEAC is available premixed with distilled water in a 50/50 concentration. If DEAC concentrate is used, Caterpillar recommends mixing the concentrate with distilled or deionized water. If distilled or deionized water is not available, use water that has the properties listed in the Caterpillar Water Quality Limits chart.Caterpillar Supplemental Coolant Additive (SCA)
Caterpillar Supplemental Coolant Additive (SCA) is effective in preventing corrosion on all metals. Caterpillar SCA also prevents the formation of mineral deposits, prevents liner cavitation, and eliminates coolant foaming.Caterpillar DEAC is formulated with the correct level of Caterpillar SCA. Additional SCA is NOT needed when the cooling system is initially filled with DEAC.Contact your Caterpillar dealer for part numbers and available container sizes.Commercial Heavy Duty (HD) Coolant/Antifreeze and SCA
If Caterpillar DEAC is not used, select a low silicate commercial HD coolant/antifreeze that meets ASTM D5345 or D4985 specifications.When a commercial HD coolant/antifreeze is used, the cooling system should be treated with three to six percent Caterpillar SCA by volume. Refer to the Caterpillar SCA Requirements for Heavy Duty Coolant/Antifreeze chart. If Caterpillar SCA is not used, select a commercial SCA. The commercial SCA must provide a minimum of 1200 mg/L or 1200 ppm (70 grains/US gal) nitrites in the final coolant mixture. Follow the coolant maintenance guidelines of the commercial SCA supplier.HD coolant/antifreezes that meet ASTM D5345 or D4985 specifications DO require SCA treatment at initial fill, and on a maintenance basis.When mixing concentrated coolants, use distilled or deionized water or use water that has the properties listed in the Caterpillar Water Quality Limits chart.Heavy Duty Coolant/Antifreeze Cooling System Maintenance
Never operate an engine without thermostats in the cooling system. Thermostats maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without thermostats.
Check the coolant/antifreeze solution (glycol content) frequently to ensure adequate anti-boil and anti-freeze protection. Caterpillar recommends the use of a refractometer for checking the

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