101603-7150 ZEXEL 9 400 615 163 BOSCH INJECTION-PUMP ASSEMBLY 9400615163 1016037150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 163 9400615163

ZEXEL 101603-7150 1016037150

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104741-1970 as _

Cross reference number

BOSCH 9 400 615 163 9400615163

ZEXEL 101603-7150 1016037150

Zexel num

Bosch num

Firm num

Name

101603-7150

9 400 615 163

INJECTION-PUMP ASSEMBLY
6SA1-T * 14BF PE6AD PE

101603-7150

9 400 615 163

1156025390 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1-T * 14BF PE6AD PE

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

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 A

Rack position 8.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 87.6 86.6 88.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9 7 11

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1120

Advance angle deg. 1 0.5 1.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT not operating. (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
----------
K=7 N1=900r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(1deg)+-5deg b=(19deg)+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

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=18deg
----------
a=(40deg)

Information:

Installation Procedure
Illustration 1 g06123834
Remove support (1) from the engine compartment.
Illustration 2 g06123840
Locate insulation (2) on the engine hood.
Illustration 3 g06123843
Raise the insulation approximately 30 mm (1.2 inch) to avoid interference with the new tank.
Illustration 4 g06123848
Loosen the worm-drive clamps and remove two hoses (3) from the DEF system. Save the cushion clamps and hardware for reuse.
Illustration 5 g06123850
(4) 428-8808 Hose Clamp
(5) 467-9633 Hose
(6) Cushion clamp (reuse)
Install hose (5) and two clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Illustration 6 g06123852
(4) 428-8808 Hose Clamp
(6) Cushion clamp (reuse)
(7) 469-6277 Hose
(8) 424-1209 Tank
Connect one end of hose (7) to the tube on the engine using clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in). Install cushion clamp (6) (previously removed) onto the hose.
Connect the other end of the hose to the upper port on tank (8). Install clamp (4). Slowly tighten the clamp to 6.6 0.2 N m (58 1.8 lb in).
Illustration 7 g06123862
(4) 428-8808 Hose Clamp
(9) 469-9636 Hose
(10) 6V-3250 O-Ring Seal
(11) 7X-1448 Elbow
Install elbow (11) and O-Ring seal (10) on the tank. Install hose (9) using two hose clamps (4). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in) while ensuring hose (9) stays at a 30 degree angle from the top tank hose.
Illustration 8 g06123868
(12) 454-4235 Plate
(13) 326-4516 Cable Tie
Secure the two hoses together using plate (12) and two cable ties (13).
Illustration 9 g06123873
(8) 424-1209 Tank
(14) 471-9825 Support As
(15) 8T-4189 Bolt
(16) 8T-4224 Hard Washer
Install support (14) in place of the original support.
Secure tank (8) to the support using two bolts (15) and two washers (16).
Install new machine, engine, and after treatment software.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.
Illustration 10 g06123878
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.