101603-4441 ZEXEL 9 400 615 082 BOSCH INJECTION-PUMP ASSEMBLY 9400615082 1016034441 1156018904

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 082 9400615082

ZEXEL 101603-4441 1016034441

ISUZU 1156018904 1156018904

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-4441 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-4441 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4840

3. GOVERNOR 105931-6820

4. SUPPLY PUMP 105220-5910

5. AUTOM. ADVANCE MECHANIS 105612-3220

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101492-0241 as _

101603-4441 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 082 9400615082

ZEXEL 101603-4441 1016034441

ISUZU 1156018904 1156018904

Zexel num

Bosch num

Firm num

Name

101603-4441

9 400 615 082

1156018904 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.6 3.55 3.65

Beginning of injection position
Drive 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 11.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60 58.4 61.6

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 H

Rack position 9.5+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 9.2 7.9 10.5

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(11.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 52.5 49.3 55.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 42.3 39.1 45.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

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. (3)RACK LIMIT: RAL
----------
T1=E57 RAL=17.3+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=43deg+-5deg b=(45deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(11.6)mm Rb=R1-0.7mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=60+-1cm3/1000st Q2=-

Timing setting

(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)-
----------
aa=14deg
----------
a=(60deg)

Information:

AFFECTED PRODUCT
Model Identification Number
797 5YW00260
797B JSM00151-00152, 220-225, 236-237, 244, 256
797F LAJ00142-00144, 189, 200-202, 227-228, 251-255, 262, 264, 266-269, 276, 283, 285, 287, 292-293, 295-296, 308, 311-314, 316-322, 327-328, 341, 343-344, 350-351, 365, 372-373, 445-446, 458-461, 464-466, 468, 476-477, 483, 491-494, 507-512, 523-525, 554-561, 569-571, 573-584, 596, 634-636, 639, 642-643
PARTS NEEDED
Qty
Part Number Description
4 8T2223 BOLT-SOCKET HD
1 8T9524 SEAL-O-RING
1 20R5566 INJECTOR GP-F -G
1 2287108 SEAL-O-RING-STOR
1 2300940 SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Perform a Fuel Status Verification Test (FSVT).
Replace injectors showing INJ-2, INJ-7 or INJ-12 code.
Refer to KENR6052 for removal and installation instructions.
To qualify for this support program;
-Machine must be operating with the Clean Fuel Module (CFM)
-Machine must be operating most current software release in SIS Web.
-Attach a Product Status Report to the claim form
-Provide the ECM Replacement files with the claim
-Conduct a review of the maintenance history of the machine to ensure no High Pressure Fuel Pump failure within two weeks of injector failure
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-12 mo 100.0% 0.0% 0.0% 100.0% 0.0% 0.0%
6001-9000 hrs,
13-24 mo 33.0% 0.0% 0.0% 50.0% 50.0% 50.0%
This is a 2.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This program can be claimed multiple times per machine.
PARTS DISPOSITION
Hold the fuel injector for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.