101605-9240 ZEXEL 9 400 615 374 BOSCH INJECTION-PUMP ASSEMBLY 9400615374 1016059240


 

Information injection-pump assembly

BOSCH 9 400 615 374 9400615374
ZEXEL 101605-9240 1016059240
101605-9240 INJECTION-PUMP ASSEMBLY
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Service parts 101605-9240 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6320
3. GOVERNOR 105419-1730
4. SUPPLY PUMP 105210-5480
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105662-1550
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6210
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105031-3910
14. NOZZLE 105015-5330
15. NOZZLE SET

Include in #1:

101605-9240 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 374 9400615374
ZEXEL 101605-9240 1016059240


Zexel num
Bosch num
Firm num
Name
101605-9240 
9 400 615 374 
  HYUNDAI
INJECTION-PUMP ASSEMBLY
6D22 K 14BE INJECTION PUMP ASSY PE6A 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   131424-4620
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   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   4.5 4.45 4.55
Beginning of injection position
Governor 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   9.4
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   112.9 109.9 115.9
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   8.8
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   93.3 90.3 96.3
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   6.8+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   13.4 10.8 16
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   155 155 165
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   8.7 6.1 11.3
Max. variation between cylinders %   0 -15 15
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 101605-9240
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Main spring setting (5)Set at delivery (6)Rack difference between N = N1 and N = N2 (7)Set idle sub-spring
----------
K=8 N1=750r/min N2=250r/min
----------

Speed control lever angle

Test data 101605-9240
F:Full speed I:Idle (1)Stopper bolt setting (2)At delivery (3)Set the pump speed at aa (4)Set the pump speed at bb.
----------
aa=750r/min bb=900r/min
----------
a=23deg+-5deg b=(2deg) c=1deg+-5deg d=5deg+-5deg

Stop lever angle

Test data 101605-9240
N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=39deg+-5deg b=53deg+-5deg

Timing setting

Test data 101605-9240
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(7deg)




Information:

The engine is turbocharged and air-to-air aftercooled (ATAAC) with direct fuel injection.The 3176 is an electronically controlled, mechanically actuated unit injector diesel engine. Timing advance is achieved by precise control of injector firing. Engine speed is controlled by adjusting the firing duration. A pulse wheel provides information to the fuel cooled ECM (Electronic Control Module) for detection of cylinder position and engine speed.The 3176 electronic engine control system was designed to provide electronic governing, automatic air fuel ratio control, torque rise shaping, injection timing control and system diagnostics. Additional benefits such as cruise control, vehicle speed limiting, low and high gears engine speed limiting (progressive shift engine speed control), PTO governor, data link and multi-torque ratings provide for additional engine fuel economy, driver comfort and serviceability.The fuel system is a mechanically actuated, electronically controlled unit injector combining the pumping, electronic fuel metering and injecting elements in a single unit to produce higher injection pressures (22,000 psi [151 600 kPa]). High injection pressures help to reduce fuel consumption and particulate emissions.The use of this type of unit injector provides total electronic control of injection timing. The injection timing is varied as a function of engine operating conditions. This optimizes the engine's performance for starting, emissions, noise, fuel consumption and driveability.A full range electronic governor is utilized and controls the fuel injection output to maintain the engine speed desired by the 3176 system. The governor functions like the Caterpillar mechanical governor in the mid-range, but includes additional features. These include programmable isochronous low idle and 20 rpm governor overrun.The 3176 has built-in diagnostics to assure that all components are functioning and operating properly. In the event of a system component deviation from programmed limits, the operator will be alerted to the condition by a dashboard mounted "Check Engine" light.A Caterpillar service tool may be used to read the numerical code of the faulty component. Intermittent faults are logged and stored in the system memory. Refer to Engine Diagnostics section of this publication for alternative methods.The cooling system consists of a gear driven pump, with one thermostat which regulates the engine coolant temperature, a plate type oil cooler and a radiator incorporating a shunt system.The 3176 does not have a cylinder block water cooling system. Instead, the cast water manifold in the spacer deck distributes 65% of the coolant volume to each of the cylinder liners and the remaining 35% flows directly to the cylinder head.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear-type pump. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high, or if either the oil cooler or the oil filter elements (paper cartridge) should become plugged.Multi-Torque Rating (if equipped)
This feature provides higher torque levels and better fuel economy while in top gear only. The 3176 electronics are able to determine when the vehicle is in top gear by calculating the engine rpm/vehicle speed ratio. A ratio of less than 26.6 will provide higher

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