101606-0190 ZEXEL 9 400 615 408 BOSCH INJECTION-PUMP ASSEMBLY 9400615408 1016060190 8976004960


 

Information injection-pump assembly

BOSCH 9 400 615 408 9400615408
ZEXEL 101606-0190 1016060190
ISUZU 8976004960 8976004960
101606-0190 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 615 408 9400615408
ZEXEL 101606-0190 1016060190
ISUZU 8976004960 8976004960


Zexel num
Bosch num
Firm num
Name
101606-0190 
9 400 615 408 
8976004960  ISUZU
INJECTION-PUMP ASSEMBLY
6HH1-S 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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4.7 4.65 4.75
Rack position
After adjusting injection quantity.
  R=A
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   -
Rack position   13
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 84.9 88.1
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   -
Rack position   9.6+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   86.5 85.5 87.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.15
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   95.5 92.3 98.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   77.5 74.3 80.7
Fixing the lever   *
Timer adjustment
Pump speed r/min   905--
Advance angle deg.   0 0 0
Load   3/5
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   855
Advance angle deg.   0.3
Load   3/5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1.5 1 2
Load   5/5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1110
Advance angle deg.   1.5 1 2
Load   3/5
Timer adjustment_05
Pump speed r/min   1450
Advance angle deg.   7 6.5 7.5
Load   5/5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-0190
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=K09
----------

Speed control lever angle

Test data 101606-0190
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101606-0190
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 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=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101606-0190
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)




Information:

Coolant
To prevent personal injury, do not step up on engine to remove the filler cap, if applicable. Use an adequate ladder.At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water. When pressure is relieved rapidly, this hot water can turn into steam.Allow cooling system components to cool before draining.Any contact with hot water or steam can cause severe burns.Check the coolant level only after the engine has been stopped and the filler cap is cool enough to remove with your bare hand.Remove the cooling system filler cap slowly to relieve pressure.Cooling system supplemental additive contains alkali. To prevent personal injury, avoid contact with the skin and eyes and do not drink.Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.Batteries
Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes.Wash hands after touching batteries and connectors. Use of gloves is recommended.Batteries give off flammable fumes which can explode.Always thaw a frozen battery before jump starting. Frozen batteries can explode.Do not smoke when observing the battery electrolyte levels.Always wear protective glasses when working with batteries.Fire or Explosion Prevention
Determine whether the engine will be operated in an environment in which combustible gases could be drawn through the air inlet system. These gases could cause the engine to overspeed, which in turn could seriously damage the engine and result in bodily injury or property damage.If your application involves the presence of combustible gases, consult your Caterpillar dealer to obtain additional information concerning protection devices suitable for the application involved.Inhaling freon gas through a lit cigarette or other smoking method, or inhaling fumes released from a flame contacting freon could cause bodily harm or death. Do not smoke when servicing, charging or working around air conditioners or where freon gas may be present.All fuels, most lubricants and some coolant mixtures are flammable.Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive.Do not smoke while refueling or in a refueling area.Always thaw a frozen battery before jump starting. Frozen batteries can explode.Do not smoke in areas where batteries are charged, or where flammable materials are stored.Batteries give off flammable fumes which can explode.Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container, in a safe place.Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.Remove all flammable materials such as fuel, oil and other debris before they accumulate on the truck engine.Do not expose the engine to flames, burning brush, etc., if at all possible.Exhaust shields (if equipped), which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly.Never disconnect any charging

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Group cross 101606-0190 ZEXEL

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Isuzu 

9 400 612 946 
1156034151 
INJECTION-PUMP ASSEMBLY
6BG1-T
101606-0190  
9 400 615 408 
8976004960 
INJECTION-PUMP ASSEMBLY
6HH1-S
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