101603-7260 ZEXEL 9 400 615 170 BOSCH INJECTION-PUMP ASSEMBLY 9400615170 1016037260 1156025710

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 170 9400615170

ZEXEL 101603-7260 1016037260

ISUZU 1156025710 1156025710

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Buy INJECTION-PUMP ASSEMBLY 101603-7260 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4590

3. GOVERNOR 105931-4981

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS 105644-0420

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6241

11. Nozzle and Holder 1-15300-142-0

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-5860

15. NOZZLE SET

Include in #1:

101603-7260 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1101 as _

Cross reference number

BOSCH 9 400 615 170 9400615170

ZEXEL 101603-7260 1016037260

ISUZU 1156025710 1156025710

Zexel num

Bosch num

Firm num

Name

101603-7260

9 400 615 170

1156025710 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * 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 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

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

Rack position
Point A R=A

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 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.3 52.7 55.9

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 6.7 9.3

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(10.8)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.3 53.3 55.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.8)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 60 56.8 63.2

Fixing the lever *

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
T1=C78
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=42deg+-5deg b=(33deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Stopper bolt setting
----------

----------
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=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.8)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.3+-1cm3/1000st Q2=(40.4)+-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)

Information:

Features and Benefits
Cat Reman Fuel Injectors and Nozzles offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these remanufactured fuel injectors and nozzles. Cat Reman Fuel Injectors and Nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Features Benefits
All critical engineering changes and updates included Improved reliability and performance
Worldwide availability through Caterpillar? parts distribution system Customer access regardless of location
Backed by Cat parts warranty Consistent support
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured Fuel Injectors and Nozzles is simple, visual, and requires no special tools. Please see the table below for applicable Core Acceptance Criteria for each Injector or Nozzle type.
Type Applicable Core Acceptance Criteria
Direct Injection Fuel Nozzles - Direct Injection (SELD0224)
Mechanical Unit Unit Injectors Mechanical (SELD0030-04)
Electronic Unit Unit Injectors - Electronic (SELD0226)
Warranty
Please consult the appropriate Cat?parts warranty statement for your area.
Availability
All of the above fuel injectors and nozzles are currently available for ordering. Some of these Reman Fuel Injectors and Nozzles are currently on initial seed support. For parts on initial seed support Antares may show "0" on-hand quantity for the Reman part number, however, orders for Reman will be filled with the new part equivalent. When Reman is the preferred option always order under the Reman part number regardless of what the system shows for on-hand. As long as the new equivalent part number has on-hand available the Reman order will be filled.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts Information application describing all Cat Reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail.
For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman Dealer website https://catreman.cat.com
If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman Technical Help Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.