Information injection-pump assembly
BOSCH
9 400 612 168
9400612168
ZEXEL
101606-0171
1016060171
ISUZU
8976004571
8976004571

Rating:
Service parts 101606-0171 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94391-291-4
12.
Open Pre:MPa(Kqf/cm2)
16.2{165}/19.6{200}
14.
NOZZLE
Cross reference number
BOSCH
9 400 612 168
9400612168
ZEXEL
101606-0171
1016060171
ISUZU
8976004571
8976004571
Zexel num
Bosch num
Firm num
Name
9 400 612 168
8976004571 ISUZU
INJECTION-PUMP ASSEMBLY
6HL1-S * K 14BF PE6AD PE
6HL1-S * 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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8620
Overflow valve opening pressure
kPa
206
206
206
Overflow valve opening pressure
kgf/cm2
2.1
2.1
2.1
Tester oil delivery pressure
kPa
225
225
225
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
14.1
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
128.5
126.9
130.1
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
Z
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
15.5
14.2
16.8
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(14.1)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
128.5
127.5
129.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
[R1+1.15
]+0.05-0
.15
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
130
126.8
133.2
Fixing the lever
*
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=N97
----------
----------
T1=N97
----------
Timer adjustment

(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle

F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
(3)Viewed from feed pump side.
----------
aa=33mm
----------
a=12deg+-5deg b=47.5deg+-3deg
----------
aa=33mm
----------
a=12deg+-5deg b=47.5deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR

Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.1)mm Vist=3.55+-0.28V
----------
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.1)mm Vist=3.55+-0.28V
----------
Timing setting

(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=6deg
----------
a=(160deg)
----------
aa=6deg
----------
a=(160deg)
Information:
Refer to the topics in the Operation & Maintenance Manual, SEBU6150, SR4 Generators and Control Panels, and the Maintenance Schedules in this manual for page numbers and information to perform the maintenance specified in the following schedules.Weekly (Before Starting Engine)
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Battery Charger - Check for proper operation Batteries - Clean/Check electrolyte level Air Starter System (if equipped) - Check lubricator oil level, air pressure and drain condensation Engine Air Cleaner - Check service indicator Block Heater - Check for proper operation, maintain 32°C (90°F) temperature Aftercooler - Inspect ATAAC Belts - Inspect/Replace Engine Protection Devices - Inspect system and gauges for proper operation Generator and Control Panel - Inspect componentsWeekly (With Engine Running)*
Walk-Around Inspection - Inspect engine for leaks and loose connections and generator louvers for proper operation Engine Crankcase - Check oil level Oil Pressure - Check gauge reading Generator - Check frequency (rpm) and generated voltageWeekly (After Stopping Engine)*
Walk-Around Inspection - Inspect engine and report malfunction and make necessary repairs Automatic Switches - Check for proper position to execute auto-start Battery Charger - Record charging amperage readingYearly (Before Starting Engine)*
Cooling System - Check coolant level, Test for concentration of supplemental coolant additive Crankcase Breather - Clean Valve Lash - Check/Adjust Governor - Inspect for leaks Governor Linkage - Check/Adjust and Lubricate Air Inlet Piping - Inspect Engine Air Cleaner - Check service indicator, Replace element if necessary Generator - Lubricate bearingYearly (With Engine Running)*
Engine Protection Devices - Inspect system and gauges for proper operation;/bs/, Record gauge readings Radiator (If Equipped) - Inspect for leaks and loose connections and louvers for proper operation Load Test - Operate the engine at a minimum of 30 percent of rated load for minimum of two hours Engine Mounts - InspectYearly (After Stopping Engine)*
Scheduled Oil Sampling (S O S) Analysis - Obtain Engine Oil and Filters - ReplaceEvery Three Years (Before Starting Engine)*
Turbocharger - Inspect/Check bearing end play and radial clearance Governor - Inspect for leaks Thermostat - Replace Coolant Hoses - Replace Cooling System - Clean/Flush coolant Batteries - ReplaceEvery Three Years (With Engine Running)*
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Protection Devices - Inspect system and gauges for proper operation, Record gauge readings Engine Crankcase - Check oil level Radiator (If Equipped) - Inspect for leaks and loose connections and louvers for proper operation Load Test - Operate at a minimum of 30 percent of rated load for minimum of two hours Exhaust System - Check for leaksEvery Three Years (After Stopping Engine)*
Walk-Around Inspection - Inspect engine and report malfunction and make necessary repairs Scheduled Oil Sampling (S O S) Analysis - Obtain Engine Oil and Filters - Replace Battery Charger - Record charging amp reading Automatic Switches - Check for proper position to execute auto-start Coolant Analysis - ObtainEvery Four Years
Drain/Replace Engine Coolant (Extended Life Coolant Only)*First Perform Previous Maintenance Items
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Battery Charger - Check for proper operation Batteries - Clean/Check electrolyte level Air Starter System (if equipped) - Check lubricator oil level, air pressure and drain condensation Engine Air Cleaner - Check service indicator Block Heater - Check for proper operation, maintain 32°C (90°F) temperature Aftercooler - Inspect ATAAC Belts - Inspect/Replace Engine Protection Devices - Inspect system and gauges for proper operation Generator and Control Panel - Inspect componentsWeekly (With Engine Running)*
Walk-Around Inspection - Inspect engine for leaks and loose connections and generator louvers for proper operation Engine Crankcase - Check oil level Oil Pressure - Check gauge reading Generator - Check frequency (rpm) and generated voltageWeekly (After Stopping Engine)*
Walk-Around Inspection - Inspect engine and report malfunction and make necessary repairs Automatic Switches - Check for proper position to execute auto-start Battery Charger - Record charging amperage readingYearly (Before Starting Engine)*
Cooling System - Check coolant level, Test for concentration of supplemental coolant additive Crankcase Breather - Clean Valve Lash - Check/Adjust Governor - Inspect for leaks Governor Linkage - Check/Adjust and Lubricate Air Inlet Piping - Inspect Engine Air Cleaner - Check service indicator, Replace element if necessary Generator - Lubricate bearingYearly (With Engine Running)*
Engine Protection Devices - Inspect system and gauges for proper operation;/bs/, Record gauge readings Radiator (If Equipped) - Inspect for leaks and loose connections and louvers for proper operation Load Test - Operate the engine at a minimum of 30 percent of rated load for minimum of two hours Engine Mounts - InspectYearly (After Stopping Engine)*
Scheduled Oil Sampling (S O S) Analysis - Obtain Engine Oil and Filters - ReplaceEvery Three Years (Before Starting Engine)*
Turbocharger - Inspect/Check bearing end play and radial clearance Governor - Inspect for leaks Thermostat - Replace Coolant Hoses - Replace Cooling System - Clean/Flush coolant Batteries - ReplaceEvery Three Years (With Engine Running)*
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Protection Devices - Inspect system and gauges for proper operation, Record gauge readings Engine Crankcase - Check oil level Radiator (If Equipped) - Inspect for leaks and loose connections and louvers for proper operation Load Test - Operate at a minimum of 30 percent of rated load for minimum of two hours Exhaust System - Check for leaksEvery Three Years (After Stopping Engine)*
Walk-Around Inspection - Inspect engine and report malfunction and make necessary repairs Scheduled Oil Sampling (S O S) Analysis - Obtain Engine Oil and Filters - Replace Battery Charger - Record charging amp reading Automatic Switches - Check for proper position to execute auto-start Coolant Analysis - ObtainEvery Four Years
Drain/Replace Engine Coolant (Extended Life Coolant Only)*First Perform Previous Maintenance Items