101601-7740 ZEXEL 9 400 614 661 BOSCH INJECTION-PUMP ASSEMBLY 9400614661 1016017740 1156013811


 

Information injection-pump assembly

BOSCH 9 400 614 661 9400614661
ZEXEL 101601-7740 1016017740
ISUZU 1156013811 1156013811
101601-7740 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 614 661 9400614661
ZEXEL 101601-7740 1016017740
ISUZU 1156013811 1156013811


Zexel num
Bosch num
Firm num
Name
101601-7740 
9 400 614 661 
1156013811  ISUZU
INJECTION-PUMP ASSEMBLY
6QA1 * K

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   11.2
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   111.5 109.5 113.5
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   11.6
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   115 114 116
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
Startup boost setting
 
Injection quantity adjustment_05
Adjusting point   E
Rack position   10.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   80.5 79.5 81.5
Max. variation between cylinders %   0 -2 2
Fixing the lever   *
Remarks
At absolute pressure 61.3 kPa {460 mmHg}
 
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 101601-7740
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL (3)Aneroid compensator absolute pressure: P1
----------
DL=6.5+-0.5mm SXL=12.4+-0.1mm P1=61.3+-0.7kPa(460+-5mmHg)
----------

Speed control lever angle

Test data 101601-7740
F:Full speed M:Minimum-maximum speed (1)Set the pump speed at aa. (At delivery) (2)Set the speed at bb. Set using two nuts.
----------
aa=1150r/min bb=550r/min
----------
a=3deg+-5deg b=11deg+-5deg

0000000901

Test data 101601-7740
F:Full load I:Idle (1)Stopper bolt setting (2)Attach the return spring to the upper hole and adjust the governor.
----------

----------
a=4deg+-5deg b=22deg+-3deg

Stop lever angle

Test data 101601-7740
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101601-7740
(A) Set screw (B) Push rod 1 1. Aneroid compensator unit adjustment (1)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=700r/min L1=(0.6~0.9)mm
----------
R1=11.6mm R2=10.2mm P1=(90.6)kPa((680)mmHg) P2=61.3+-0.7kPa(460+-5mmHg) Q1=115+-1cm3/1000st Q2=80.5+-1cm3/1000st




Information:


Caterpillar recommends that the coolant mixture contain a minimum of 30% Caterpillar Antifreeze (or equivalent) with 70% distilled or deionized water to maintain an adequate cavitation temperature for efficient water pump performance. Antifreeze concentration should be selected to provide protection to the lowest expected outside (ambient) temperature.Check the specific gravity of the antifreeze solution frequently in cold weather to ensure adequate freeze protection. Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C). Antifreeze concentrations above 60% antifreeze to 40% water are NOT recommended because the higher concentrations limit the ability of the coolant mixture to absorb supplemental coolant additive.
Use Caterpillar Antifreeze or any low silicate (ethylene or propylene glycol) antifreeze that meets ASTM D4985-89 (GM Specification 6038-M) requirements. Most commercial antifreezes are formulated for gasoline engine applications and have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines.Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Adding pure undiluted antifreeze as a makeup solution for cooling system top-off is an unacceptable practice. Add antifreeze premixed with acceptable water to the same freeze protection as your cooling system. Use the Antifreeze Concentration chart to assist in determining the concentration of Caterpillar Antifreeze to use. Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester (for Caterpillar products) to ensure adequate freeze protection. The testers are identical except temperature scales (°C or °F) and give immediate accurate readings for antifreeze/coolants that contain ethylene or propylene glycol. Both testers are available at your Caterpillar dealer.
If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (5P0957 or 5P3514) rather than the hydrometer-type tester commercially available. The hydrometer-type tester can be used to test ethylene glycol based antifreeze.
Supplemental Coolant Additive (Conditioner or Inhibitor)
The cooling system MUST contain supplemental coolant additives (conditioner or inhibitor) to control corrosion, cavitation and deposits. It is also necessary to prevent rust, scale, pitting and/or corrosion of engine parts contacted by coolant. The cooling system should be protected with a minimum of 3% concentration at all times, regardless of the concentration of antifreeze. Use supplemental coolant additive liquid OR an element (if equipped) to maintain a 3-6% concentration in the cooling system.
Never use antifreeze/water coolant only, in Caterpillar engines without supplemental coolant additive regardless of antifreeze concentration.Caterpillar or other manufacturer's products can be used as the supplemental coolant additive. DO NOT mix Caterpillar Supplemental Coolant Additive (Conditioner) liquid or elements with the other commercial products available; select a cooling system treatment and use it exclusively.Excessive concentration of supplemental coolant additive can form deposits which may cause engine damage, reduce the engine's heat transfer characteristics and could also accelerate water pump seal wear.
Use the 8T5296 Test Kit to check

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