Information injection-pump assembly
BOSCH
9 400 615 156
9400615156
ZEXEL
101603-7032
1016037032
Rating:
Service parts 101603-7032 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-142-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-7032
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-1535
as _
Cross reference number
BOSCH
9 400 615 156
9400615156
ZEXEL
101603-7032
1016037032
Zexel num
Bosch num
Firm num
Name
101603-7032
9 400 615 156
INJECTION-PUMP ASSEMBLY
6BG1 * 14BE PE6A PE
6BG1 * 14BE PE6A PE
101603-7032
9 400 615 156
1156024832 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 * 14BE PE6A PE
6BG1 * 14BE PE6A 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
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)
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
3.6
3.55
3.65
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
-
Rack position
10.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
54.2
52.6
55.8
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.
8.4
7.1
9.7
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(10.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
54.2
53.2
55.2
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.6)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
66.8
63.6
70
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
87
87
119
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1390--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1340
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1530
Advance angle
deg.
3.5
3
4
Remarks
Finish
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.
----------
T1=C78
----------
----------
T1=C78
----------
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=42deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Stopper bolt setting
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-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=131154-2520 ST=A267 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131154-2520 ST=A267 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
0000001601 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=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.2+-1cm3/1000st Q2=(39.8)+-1.6cm3/1000st
----------
N1=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.2+-1cm3/1000st Q2=(39.8)+-1.6cm3/1000st
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=12deg
----------
a=(60deg)
----------
aa=12deg
----------
a=(60deg)
Information:
REM02-13
Reman
May 2002 RELOCATION OF SERVICE CENTER FOR 3600 FUEL INJECTORS Announcement Caterpillar is pleased to announce the relocation of the 3600 Fuel Injector Service Center from Booneville, MS to Caterpillar?s Fuel Injector Remanufacturing facility located in Nuevo Laredo, Mexico effective June 01, 2002. This Service Center provides a 3600 Fuel Injector ?Repair and Return? service, principally for dealers in North and South America. This move will in no way effect the excellent service Dealers have come to expect from this program. Injectors in transit to the Boonville, MS facility will be redirected to the Nuevo Laredo facility.Program Dealers can continue to send their 3600 injectors, tagged with Caterpillar? form number 00040279-00 directly to the new address listed below. New forms are being printed with a corrected ship to address. In the interim, Dealers should continue to use the old form. The Dealer will continue to be responsible for freight and insurance to and from the Service Center. The Center will, as in the past, service the injectors and return them, along with an individual certificate of conformity, to wherever the dealer requires. A database with key information on each injector will continue be maintained at the Service Center.The injectors will receive an initial inspection within five days of receipt. Normal turnaround time for the repaired injectors will be 20 ? 30 days. However, should the injectors be required urgently, this can be specified as a special instruction on the shipping tag and accommodated with a premium charge. Special return shipping instructions, such as airfreight, should also be communicated on the shipping tag. If not specified, the repaired injectors will be returned via standard surface freight to the dealer?s main office address.Shipping Location
Caterpillar Inc.
C/O Tecmosa/Dicex International
1101 Black Diamond
International Commerce Center
Laredo, TX 78045
Attn: 3600 Injector Service Center
The new Service Center Customer Service telephone number is: 1877-536-5460.
Features And BenefitsThe service provided will be a ?repair and return? service of the customer?s serialized injector, as opposed to a Reman exchange for a customer?s core. The customer will get his own injector back. It will have been completely disassembled with each component inspected, and after re-assembly, 100% tested against new specifications. A technical report will be completed and returned with each injector to help the dealer analyze any fuel system related problems, which if corrected could possibly help extend the life of the injectors.This service does not replace the remanufactured injector program. It complements it as another repair option offered at a price comparable to the competition. The dealer may choose to have the injectors cleaned or repaired. Or, depending on the need, a remanufactured injector can still be purchased. In this case the Service Center will notify the dealer and transfer the core to Reman, establishing a core credit for the dealer. This Service Center will provide one more way to lower the customer?s owning and operating expenses.Price A flat labor charge of $200 US plus any new components replaced will be
Have questions with 101603-7032?
Group cross 101603-7032 ZEXEL
Isuzu
Isuzu
101603-7032
9 400 615 156
INJECTION-PUMP ASSEMBLY
6BG1
6BG1
Isuzu
101603-7032
9 400 615 156
1156024832
INJECTION-PUMP ASSEMBLY
6BG1
6BG1