101603-7510 ZEXEL 9 400 615 189 BOSCH INJECTION-PUMP ASSEMBLY 9400615189 1016037510 1156026900

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 189 9400615189

ZEXEL 101603-7510 1016037510

ISUZU 1156026900 1156026900

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Buy INJECTION-PUMP ASSEMBLY 101603-7510 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7510 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3140

3. GOVERNOR 105400-4320

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 105100-6771

11. Nozzle and Holder 1-15300-161-1

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105031-4781

14. NOZZLE 105015-6430

15. NOZZLE SET

Include in #1:

101402-4161 as _

101603-7510 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 189 9400615189

ZEXEL 101603-7510 1016037510

ISUZU 1156026900 1156026900

Zexel num

Bosch num

Firm num

Name

101603-7510

9 400 615 189

1156026900 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 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 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 10.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 123.6 122.6 124.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.7+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.1 7.1 11.1

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=12 N1=1100r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=10deg+-5deg b=25deg+-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:

Parts Location
Illustration 2 g01631813
(A) Flywheel (B) Fender Group (C) Tank Group (1) 319-8929 Diesel Particulate Filter Gp (2) 329-1696 Tube (3) 329-1701 Tube As (4) 295-3044 Exhaust Support Gp (5) 8T-4223 Hard Washer (6) 8T-4183 Bolt (7) 270-0112 Bellows (8) 7E-3870 Muffler Clamp (9) 247-5011 Pipe Clamp (10) 9Y-8315 Pipe Clamp (11) 8S-5120 Extension Pipe (12) 7S-4994 Rain Cap As (13) 241-6170 Plug (14) 8T-6765 Pipe Plug Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01630053
(4) 295-3044 Exhaust Support Gp (Lower half) (5) 8T-4223 Hard Washer (6) 8T-4183 Bolt
Install the lower half of each new 295-3044 Exhaust Support Gp (4) on top of the hood, towards the right side of the cab, by using four new 8T-4183 Bolts (6), and four new 8T-4223 Hard Washers (5). Refer to Illustration 3.
Illustration 4 g01630056
(1) 319-8929 Diesel Particulate Filter Gp
Install the new 319-8929 Diesel Particulate Filter Gp (1) onto the lower half of exhaust support group (4). Refer to Illustration 4.
Illustration 5 g01630074
(4a) Upper half (Exhaust support group) (4b) Bolt (4c) Hard washer (4d) Weld nut
Install the upper half (4a) of exhaust support group by using two bolts (4b), two hard washers (4c), and two weld nuts (4d). Repeat for the other exhaust support group. Refer to Illustration 5.
Illustration 6 g01630094
(2) 329-1696 Tube (3) 329-1701 Tube As (7) 270-0112 Bellows (8) 7E-3870 Muffler Clamp
Install the new 329-1696 Tube (2) to the inlet module tube of the diesel particulate filter group by using one new 7E-3870 Muffler Clamp (8). Refer to Illustration 6.
Install the new 270-0112 Bellows (7) to tube (2) by using one new 7E-3870 Muffler Clamp (8). Refer to Illustration 6.
Install the new 329-1701 Tube Assembly (3) to bellows (7) by using one new 7E-3870 Muffler Clamp (8). Refer to Illustration 6.
Illustration 7 g01630133
(9) 247-5011 Pipe Clamp (11) 8S-5120 Extension Pipe
Install 8S-5120 Extension Pipe (11) to the outlet module tube of the diesel particulate filter group by using a new 247-5011 Pipe Clamp (9). Refer to Illustration 7.
Illustration 8 g01630173
(12) 7S-4994 Rain Cap As
Install the new 7S-4994 Rain Cap Assembly (12) on extension pipe (11). Refer to Illustration 8.
Illustration 9 g01630234
(13) 241-6170 Plug (14) 8T-6765 Pipe Plug
Install a new 241-6170 Plug (13) and a new 8T-6765 Pipe Plug (14) on tube assembly (3) at the respective slots provided. Refer to Illustration 9.
Reconnect the drain lines.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" for information regarding the installation and the operation of the exhaust monitor.The exhaust monitor is a device designed to monitor the Caterpillar DPF system continuously. The exhaust monitor provides critical information to the vehicle operator and maintenance