101602-5000 ZEXEL 9 400 611 171 BOSCH INJECTION-PUMP ASSEMBLY 9400611171 1016025000 220401650a

Changing Filter Element
A 1U-9578 Repair Kit (Nozzle Tester) is available to maintain the tester. The repair kit contains a new filter along with seals, gaskets, and instructions on how to use the kit. Do not reuse seals and gaskets when changing the filter. Always use new seals and gaskets.Calibration Fluid
The calibration fluid should be changed every three months or after testing 50 nozzles. The fluid should also be changed whenever inaccurate test results are suspected.Inaccurate test results can be caused by fluid with improper specific gravity, viscosity, visible contamination, fluid that foams, or discolored fluid.The fluid should also be checked for the correct viscosity. It is a good practice to test new calibration fluid for the correct viscosity and specific gravity. Use a 9U-7840 Test Kit to check calibration fluid.
Do not refill the nozzle tester with test oil that has been pumped through a fuel injection nozzle. Nozzles contain residual amounts of diesel fuel that is pumped out when tested. The diesel fuel mixes with and contaminates the test oil. Using this diesel fuel test oil combination will damage the nozzle tester.
9U-7840 Test Kit For Checking Fluid Viscosity Calibration fluid will last longer if the nozzles are cleaned prior to testing. As the fluid in the tester becomes contaminated, the accuracy of the test results are decreased.Changing Calibration Fluid
1. Completely drain the reservoir and any fluid contained in the pump mechanism. Special care must be taken for the disposal of the calibration fluid. Recent regulations prohibit the dumping of oil; all oil must be properly disposed.2. Thoroughly clean the reservoir using an 8T-9011 Component Cleaner or equivalent and clean towels.3. Install a new 8T-5313 Filter Element (10 micron). A new filter element should be installed whenever the calibration fluid is changed (even if less than 3 months).4. Fill the reservoir with clean calibration fluid (refer to the chart for part numbers).Nozzle Tester Pressure Gauges
Pressure gauges in the nozzle tester should be checked for accuracy every 12 months or whenever inaccurate test results are suspected. Gauges should also be checked whenever a gauge is damaged or the needle does not return to zero. Record all data on the data sheets in the "Forms" section.1. Remove pressure gauge from the nozzle tester.2. Install gauge adapter from 5P-8558 Calibrating Group Pressure Gauge onto pressure gauge.3. Connect pressure to tester port.4. Use a 1U-5230 Hand Pump to apply pressure to the gauge. Increase the pressure to 25% of the pressure gauges capacity.5. Check the actual gauge pressure with the tester gauge reading. The two pressures should be within two percent of each other.6. Repeat Step 5 at 50, 75 and 100 percent increments. Each increment should be within two percent of the tester gauge reading.7. If the pressure is not within two percent, the pressure gauge should be replaced.Check Tester For Leakage
Before testing any nozzle, check the tester for obvious external leakage. Leakage in the tester will give inaccurate test results, causing good nozzles to be rejected.Always check the tester for leakage