101603-7288 ZEXEL F 01G 09U 047 BOSCH INJECTION-PUMP ASSEMBLY f01g09u047 1016037288 8943965705

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 047 f01g09u047

ZEXEL 101603-7288 1016037288

ISUZU 8943965705 8943965705

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Buy INJECTION-PUMP ASSEMBLY 101603-7288 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7288 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5010

3. GOVERNOR 105931-7623

4. SUPPLY PUMP 105210-5090

5. AUTOM. ADVANCE MECHANIS 105643-0610

6. COUPLING PLATE 105661-0781

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5000

11. Nozzle and Holder 8-94397-054-0

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE 105017-1050

15. NOZZLE SET

Include in #1:

101603-7288 as INJECTION-PUMP ASSEMBLY

Include in #2:

104134-3010 as _

Cross reference number

BOSCH F 01G 09U 047 f01g09u047

ZEXEL 101603-7288 1016037288

ISUZU 8943965705 8943965705

Zexel num

Bosch num

Firm num

Name

101603-7288
101603-7289

F 01G 09U 047

8943965705 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-N * 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)
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 3.7 3.65 3.75

Rack position
After adjusting injection quantity. R=A

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 -

Rack position 12.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63 61.4 64.6

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 260 260 260

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(12.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 63 62 64

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 71.1 67.9 74.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 102 102 134

Fixing the lever *

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 2 1.5 2.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

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.
----------
T1=G23
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=(40deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=67mm
----------
a=16deg+-5deg b=29deg+-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=131154-1320 ST=A255 L1=1mm L2=3.7+-0.05mm a1=+-14% a2=+-2.5%
----------

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=10deg
----------
a=(160deg)

Information:

TERMINATION DATE
31Jul2009
PROBLEM
The existing HEUI pump, Injector O-rings, and/or Fuel Pressure Regulator can fail on certain On-Highway Mass Transit Bus Engines.
AFFECTED PRODUCT
Model Identification Number
C9 MTB01000, 1005, 1007-1014, 1016-1078, 1087-1090, 1093-1095, 1097, 1099, 1101, 1103-1104, 1109-1110, 1117-1129, 1131-1134, 1136, 1140-1141, 1143-1144, 1147, 1149-1150, 1159-1162, 1172-1176, 1179-1181, 1183-1184, 1186, 1188, 1190-1196, 1198-1202, 1205-1208, 1217, 1221, 1227-1233, 1235, 1238, 1240-1241, 1244-1245, 1248-1252, 1255-1256, 1261-1265, 1267, 1269, 1272-1273, 1278, 1285-1289, 1293, 1298, 1301-1306, 1311-1322, 1324-1343, 1345-1353, 1355-1363, 1365-1366, 1368, 1371-1372, 1374, 1380-1381, 1384-1386, 1396, 1398-1400, 1402, 1404, 1406, 1409, 1411, 1415, 1418, 1420-1421, 1425-1426, 1428-1429, 1431-1432, 1434-1464, 1467-1468, 1470, 1473-1474, 1476-1477, 1480, 1482-1483, 1486-1489, 1491-1493, 1497-1498, 1521, 1555, 1558-1560, 1654-1656, 1687-1689, 1700-1706, 1837-1842, 1853-1858, 1869-1878, 1884-1886, 1893, 1896-1897, 1899, 1918, 1921, 1924-1926, 1928-1929, 1931-1943, 1992-1993, 1996-1997, 2001, 2006
PARTS NEEDED
Qty
Part Number Description
1 6V4589 SEAL-O-RING
1 1093207 SEAL-O-RING
2 1482903 SEAL-O-RING
1 1495240 RING-BACKUP
1 2930730 RING-BACKUP
1 2948620 REGULATOR AS.
1 3120678 PUMP GP -B
ACTION REQUIRED
Follow SENR9674 Disassembly and Assembly Guide for installation of updated HEUI Pump, Injector O-rings, and Fuel Pressure Regulator.
Reference SEBD6792 for correct orientation of Injector O-rings.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-12000 hrs 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 7.5-hour job
*Dealer to perform most economical repair*
Description_________SMCS__________Hours
R&I Injectors_____1290-010-S______4.2hrs
Wash______________1290-074________0.3hrs
Test After________1290-030________0.5hrs
R&I HEUI PUMP_____1714-010________1.1hrs
Pump Test After___1714-030________0.5hrs
R&I Regulator_____1715-010________0.9hrs
*Exception may be considered and claimed depending on chassis type*
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.