101603-7351 ZEXEL 9 400 615 176 BOSCH INJECTION-PUMP ASSEMBLY 9400615176 1016037351 1156025871

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 176 9400615176

ZEXEL 101603-7351 1016037351

ISUZU 1156025871 1156025871

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104741-6831 as _

Cross reference number

BOSCH 9 400 615 176 9400615176

ZEXEL 101603-7351 1016037351

ISUZU 1156025871 1156025871

Zexel num

Bosch num

Firm num

Name

101603-7351

9 400 615 176

1156025871 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.2 52.6 55.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 8.4 7.1 9.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.2 53.2 55.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.6)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 66.8 63.6 70

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 87 55 119

Fixing the lever *

Timer adjustment

Pump speed r/min 1390--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1340

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1530

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=C78
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Stopper bolt setting (2)Upper lever angle
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (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. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.2+-1cm3/1000st Q2=(39.8)+-1.6cm3/1000st

0000001601 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-2520 ST=A267 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(60deg)

Information:

This Revised Service Letter replaces the 20Nov2008 Service Letter. Changes have been made to Parts Needed Description.
TERMINATION DATE
30Nov2010
PROBLEM
The existing governor linkage can separate at the riveted joint on certain C1.6 engines. If the existing governor linkage fails, it can result in loss of engine speed governing.
AFFECTED PRODUCT
Model Identification Number
C1.6 C1M00596-00703, 740-883
PARTS NEEDED
Qty
Part Number Description
1 2152619 GASKET
1 2908469 LEVER AS
1 2952235 GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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
Gain access to engine front cover and fuel pump. Replace the existing governor linkage using the following steps.
Refer to service manual module RENR2424.
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to service manual module RENR2424.
1. Remove fuel injection pump. Refer to SMCS 1251-011 (Fuel Injection Pump-Remove).
2. Remove crankshaft pulley. Refer to SMCS 1205-010 (Crankshaft Pulley-Remove and Install).
3. Remove engine front cover. Refer to SMCS 1151-011 (Housing (Front) Remove).
4. Remove fuel injection pump linkage from housing. Refer to SMCS 1151-015 (Housing (Front)-Disassemble).
5. Install new 290-8469 fuel injection pump linkage. Refer to 'Installation of fuel injection pump linkage' within SMCS 1151-016 (Housing (Front)-Assemble).
6. Install engine front cover with new gasket. Refer to SMCS 1151-012 (Housing (Front)-Install).
7. Install crankshaft pulley. Refer to SMCS 1205-010 (Crankshaft Pulley - Remove and Install).
8. Install fuel injection pump. Refer to SMCS 1251-012 (Fuel Injection Pump - Install).
9. Run engine to ensure correct operation. Check for any signs of leaks.
10. Check low and high idle, and reset appropriately.
11. Refit any machine parts that were removed to gain access to engine front cover and fuel pump.