101603-7603 ZEXEL 9 400 615 199 BOSCH INJECTION-PUMP ASSEMBLY 9400615199 1016037603 8943969283

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 199 9400615199

ZEXEL 101603-7603 1016037603

ISUZU 8943969283 8943969283

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Buy INJECTION-PUMP ASSEMBLY 101603-7603 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7603 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105931-7993

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0720

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5084

11. Nozzle and Holder 8-94397-483-2

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1090

15. NOZZLE SET

Include in #1:

101401-4050 as _

101603-7603 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 199 9400615199

ZEXEL 101603-7603 1016037603

ISUZU 8943969283 8943969283

Zexel num

Bosch num

Firm num

Name

101603-7603

9 400 615 199

8943969283 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-S 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)
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 4.2 4.15 4.25

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 11.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69 67.4 70.6

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 9.8+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 18.2 16.9 19.5

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(11.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69 68 70

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 103 103 135

Fixing the lever *

Timer adjustment

Pump speed r/min (1220)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1.3 0.8 1.8

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
----------
T1=G16
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=12.5deg+-5deg b=(45deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-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=131153-4520 ST=A724 L1=1mm L2=4.2+-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)- (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Pointer stamping (9)Timing device stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg
----------
a=(150deg) b=1deg

Information:

Caterpillar: Confidential Yellow
PSP FOR INSTALLING NEW ROCKER ARM BUTTONS THAT OPERATE WITH INJECTOR TAPPETS THAT ARE NOT FLAT ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PS0417 - MAILED US AND CANADA, CACO, COFA, BRAZIL, LIMITED CFEL, LIMITED COSA
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
U-232 A-149 AU-150 B-38 E-99.1 O-142.1 1123 PS0417 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0417" as Part Number, "7755" as Group Number, and "96" as Description Code. This Program cancels and replaces the April 24, 1989 Service Letter - PS0374. Termination Date
December 31, 1991
Problem
The 4W9294 Rocker Arm Button may break and fall off the fuel injector rocker arm. New buttons can be installed that will operate with injector tappets that are not flat. It is no longer necessary to change injectors when circular wear patterns show up on the rocker arm buttons.
Affected Product
Model Identification Number 3606 8RB306-335 3608 6MC246-264 3612 9RC16-46 3616 1PD18-23
Parts Needed
Note: Quantities Per Cylinder ***** Parts for use on failed cylinders only ***** 1 - 0R5738 Fuel Injector Group or 1 - 0R5510 Fuel Injector Group 1 - 7W7226