101605-0340 ZEXEL 9 400 613 437 BOSCH INJECTION-PUMP ASSEMBLY 9400613437 1016050340 1156035040


 

Information injection-pump assembly

BOSCH 9 400 613 437 9400613437
ZEXEL 101605-0340 1016050340
ISUZU 1156035040 1156035040
101605-0340 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101605-0340 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-0340 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8550
3. GOVERNOR 105411-2680
4. SUPPLY PUMP 105220-7230
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156643-1720
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-8341
11. Nozzle and Holder 1-15300-432-1
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}
13. NOZZLE-HOLDER 105041-4410
14. NOZZLE
15. NOZZLE SET 105019-2900

Include in #1:

101605-0340 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 437 9400613437
ZEXEL 101605-0340 1016050340
ISUZU 1156035040 1156035040


Zexel num
Bosch num
Firm num
Name
101605-0340 
101605-0341 
9 400 613 437 
1156035040  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-T * 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   134424-4120
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   4.2 4.15 4.25
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   A
Rack position   10.3
Pump speed r/min   975 975 975
Average injection quantity mm3/st.   89.5 88 91
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   74.6 74.6
Boost pressure mmHg   560 560
Injection quantity adjustment_02
Adjusting point   -
Rack position   8+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   15 13.7 16.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   10.5++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   70 65 75
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R1-0.7
Boost pressure kPa   37.3 33.3 41.3
Boost pressure mmHg   280 250 310
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(10.3)
Boost pressure kPa   61.3 54.6 68
Boost pressure mmHg   460 410 510

Test data Ex:

Governor adjustment

Test data 101605-0340
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=9 BCL=0.7+-0.1mm
----------

Speed control lever angle

Test data 101605-0340
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=2deg+-5deg b=16deg+-5deg

Stop lever angle

Test data 101605-0340
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101605-0340
Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

Test data 101605-0340
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(100deg)




Information:


Caterpillar does not recommend checking actual engine bearing clearances, particularly on small engines, because of the possibility of obtaining inaccurate results, and the possibility of damaging the bearing or journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness.
If the crankshaft journals and bores for the block and rods were measured at disassembly and found to be within specifications, no further checks are necessary when using the correct bearings. However, if the serviceman still wants to measure the bearing clearances, Plastigage is an acceptable method. Plastigage is less accurate on small diameter journals where clearances are less than 0.10 mm (0.004 in.).
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
1. The serviceman must be very careful to use Plastigage correctly. The following points must be remembered:a. Make sure that the backs of the bearings and the bores are clean and dry.b. The bearing locking tabs must be properly seated in their slots.c. The crankshaft must be free of oil where it is in contact with the Plastigage.d. If the main bearing clearances are checked with the engine upright or on its side, the crankshaft must be supported. Use a jack under an adjacent crankshaft counterweight and hold the crankshaft against the crown of the bearing. If the crankshaft is not supported, the weight of the crankshaft will cause incorrect readings.e. Put a piece of Plastigage on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.f. Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.g. Do not turn the crankshaft with the Plastigage installed. When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major width to make sure they are within the specification range.h. Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. See the photograph that illustrates this.i. Remove all the Plastigage before reinstalling the cap.

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