Information injection-pump assembly
BOSCH
9 400 613 437
9400613437
ZEXEL
101605-0340
1016050340
ISUZU
1156035040
1156035040

Rating:
Service parts 101605-0340 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-432-1
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/19.6{200}
14.
NOZZLE
Cross reference number
BOSCH
9 400 613 437
9400613437
ZEXEL
101605-0340
1016050340
ISUZU
1156035040
1156035040
Zexel num
Bosch num
Firm num
Name
9 400 613 437
1156035040 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-T * K 14BF PE6AD PE
6BG1-T * K 14BF PE6AD PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
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.
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

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
----------
----------
K=9 BCL=0.7+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=2deg+-5deg b=16deg+-5deg
----------
----------
a=2deg+-5deg b=16deg+-5deg
Stop lever angle

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)
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)
0000001501 TAMPER PROOF

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)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
Timing setting

(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)
----------
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.