101603-7160 ZEXEL 9 400 615 164 BOSCH INJECTION-PUMP ASSEMBLY 9400615164 1016037160 1156025400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 164 9400615164

ZEXEL 101603-7160 1016037160

ISUZU 1156025400 1156025400

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Buy INJECTION-PUMP ASSEMBLY 101603-7160 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3140

3. GOVERNOR 105400-5440

4. SUPPLY PUMP 105210-4780

5. AUTOM. ADVANCE MECHANIS 105643-0510

6. COUPLING PLATE 105662-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5171

11. Nozzle and Holder 1-15300-186-1

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-6670

15. NOZZLE SET

Include in #1:

101603-7160 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-1971 as _

Cross reference number

BOSCH 9 400 615 164 9400615164

ZEXEL 101603-7160 1016037160

ISUZU 1156025400 1156025400

Zexel num

Bosch num

Firm num

Name

101603-7160

9 400 615 164

1156025400 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1-T K 14BF INJECTION PUMP ASSY 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 10.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 115.4 114.4 116.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.4+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10 8 12

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 1100

Advance angle deg. 0.6 0.1 1.1

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

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
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Seal at shipping.
----------

----------
a=(27deg)+-5deg b=(9deg)+-5deg c=32deg+-3deg

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=16deg
----------
a=(40deg)

Information:

Installation Procedure
Illustration 1 g06124125
Remove plate (1) and discard. Save the hardware and hook assembly (2) for reuse.
Illustration 2 g06124137
(3) 5I-3822 Plate
Weld plate (3) in the location specified in Illustration 2.
Illustration 3 g06124150
Remove two hoses (4).
Illustration 4 g06124157
(5) 467-9635 Hose
(6) 428-8808 Hose Clamp
(7) 418-2057 Hose
(8) 467-9634 Hose
(9) 5P-4924 Elbow
(10) 6V-3250 O-Ring Seal
(11) 424-1209 Tank
Install hose (7) and two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install one end of hose (5) on the coolant tube and the other on tank (11). Secure the hose using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install elbow (9) and O-ring (10) onto tank (11). Tighten the elbow to 28 4 N m (21 3 lb ft).
Install hose (8) as shown using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Ensure the hoses connected to the tank are in parallel as shown in view D-D.
Illustration 5 g06124173
(12) 326-4516 Cable Tie
(13) 454-4235 Plate
Secure the hoses as shown using two cable ties (12) and plate (13).
Illustration 6 g06124183
(14) 511-8273 Sheet As
Install sheet (14) and hook assembly (2) using the saved hardware.
Illustration 7 g06124176
(11) 424-1209 Tank
(15) 467-9640 Plate As
(16) 8T-4136 Bolt
(17) 8T-4121 Hard Washer
(18) 8T-4189 Bolt
(19) 8T-4224 Hard Washer
Install plate assembly (15) using three bolts (16) and three washers (17).
Mount tank (11) onto plate (15) using two bolts (18) and two washers (19).
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). SIS web only displays the latest available flash file.
Illustration 8 g06123932
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.