Information injection-pump assembly
BOSCH
9 400 613 471
9400613471
ZEXEL
101606-0590
1016060590
ISUZU
1156035060
1156035060

Rating:
Service parts 101606-0590 INJECTION-PUMP ASSEMBLY:
1.
_
7.
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
Include in #1:
101606-0590
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6070
as _
Cross reference number
BOSCH
9 400 613 471
9400613471
ZEXEL
101606-0590
1016060590
ISUZU
1156035060
1156035060
Zexel num
Bosch num
Firm num
Name
101606-0590
9 400 613 471
1156035060 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-T K 14BF INJECTION PUMP ASSY PE6AD PE
6BG1-T K 14BF INJECTION PUMP ASSY 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
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
84.5
83
86
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
13.5
12.2
14.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
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
D
Rack position
10.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
95
90
100
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1300++
Advance angle
deg.
0
0
0
Remarks
Do not advance until starting N = 1300.
Do not advance until starting N = 1300.
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
1
1
1
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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)Rack difference between N = N1 and N = N2
----------
K=12 N1=1075r/min N2=520r/min
----------
----------
K=12 N1=1075r/min N2=520r/min
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=21deg+-5deg
----------
----------
a=3deg+-5deg b=21deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=13deg+-5deg b=53deg+-5deg
----------
----------
a=13deg+-5deg b=53deg+-5deg
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=(90deg)
----------
aa=6deg
----------
a=(90deg)
Information:
Maintenance Recommendations
Caterpillar Inc. truck engines are certified by the United States Environmental Protection Agency (EPA) to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture.Efficiency of emission control and engine performance depends on adherence to proper operation and maintenance recommendations AND use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be made by your authorized Caterpillar dealer.Various chemical fuel additives claiming to reduce visible smoke are available commercially. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require that engines be certified without smoke depressants.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the owner that the use of such parts will not adversely affect emission levels.Regular maintenance intervals, along with special emphasis on the following items, are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the Maintenance Section of this manual. If the engine is operating under severe conditions, adjust the maintenance schedule accordingly. See your authorized Caterpillar dealer to help analyze your specific application, operating environment and maintenance schedule adjustments.The following is an explanation of maintenance for emission-related components. See the Maintenance Schedule for the specific interval for the following items. ELECTRONIC UNIT INJECTORS - Fuel nozzles are subject to tip wear as a result of fuel contamination. This damage can cause an increase in fuel consumption, the engine to emit black smoke, misfire or run rough. Inspect and replace if necessary. Fuel injectors can be tested by an authorized Caterpillar truck engine dealer. TURBOCHARGER - Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Schedule. AIR/FUEL RATIO CONTROL - This component is a device to control the smoke emission of an engine during its operation when low inlet manifold pressure exists.Slow engine response and low power may indicate a need for adjustment or repair. Your Caterpillar dealer is equipped with the necessary tools, personnel and procedures to perform this service.Owner is encouraged to keep adequate maintenance records, but the absence of such, in and of itself, will not invalidate the warranty.The vehicle owner may perform routine maintenance, repairs and other non warranty work or have it done at any repair facility. Such non warranty work need not be performed at a designated warranty station in order for the warranty to remain in force.Customer Assistance-Emission Control Systems Warranty
Caterpillar Inc. aims to ensure that the Emission Control Systems warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, call or write:Caterpillar Inc.
Manager,
Caterpillar Inc. truck engines are certified by the United States Environmental Protection Agency (EPA) to comply with smoke and gaseous emission standards prescribed by Federal laws at the time of manufacture.Efficiency of emission control and engine performance depends on adherence to proper operation and maintenance recommendations AND use of recommended fuels and lubricating oils. It is recommended that major adjustments and repair be made by your authorized Caterpillar dealer.Various chemical fuel additives claiming to reduce visible smoke are available commercially. Although additives have been used by individuals to solve some isolated smoke problems in the field, they are not recommended for general use. Federal smoke regulations require that engines be certified without smoke depressants.The corrective steps taken immediately on discovery of worn parts, which may affect emission levels, will help assure proper operation of emission control systems. The use of genuine Caterpillar parts is recommended. Suppliers of non-Caterpillar parts must assure the owner that the use of such parts will not adversely affect emission levels.Regular maintenance intervals, along with special emphasis on the following items, are necessary to keep exhaust emissions within acceptable limits for the useful life of the engine. Refer to the Maintenance Section of this manual. If the engine is operating under severe conditions, adjust the maintenance schedule accordingly. See your authorized Caterpillar dealer to help analyze your specific application, operating environment and maintenance schedule adjustments.The following is an explanation of maintenance for emission-related components. See the Maintenance Schedule for the specific interval for the following items. ELECTRONIC UNIT INJECTORS - Fuel nozzles are subject to tip wear as a result of fuel contamination. This damage can cause an increase in fuel consumption, the engine to emit black smoke, misfire or run rough. Inspect and replace if necessary. Fuel injectors can be tested by an authorized Caterpillar truck engine dealer. TURBOCHARGER - Check for any unusual sound or vibration in the turbocharger. Inspect inlet and exhaust piping and connections. Check bearing condition and perform maintenance as described in the Maintenance Schedule. AIR/FUEL RATIO CONTROL - This component is a device to control the smoke emission of an engine during its operation when low inlet manifold pressure exists.Slow engine response and low power may indicate a need for adjustment or repair. Your Caterpillar dealer is equipped with the necessary tools, personnel and procedures to perform this service.Owner is encouraged to keep adequate maintenance records, but the absence of such, in and of itself, will not invalidate the warranty.The vehicle owner may perform routine maintenance, repairs and other non warranty work or have it done at any repair facility. Such non warranty work need not be performed at a designated warranty station in order for the warranty to remain in force.Customer Assistance-Emission Control Systems Warranty
Caterpillar Inc. aims to ensure that the Emission Control Systems warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control Systems Warranty, call or write:Caterpillar Inc.
Manager,
Have questions with 101606-0590?
Group cross 101606-0590 ZEXEL
Isuzu
101606-0590
9 400 613 471
1156035060
INJECTION-PUMP ASSEMBLY
6BG1-T
6BG1-T