101603-7643 ZEXEL 9 400 615 202 BOSCH INJECTION-PUMP ASSEMBLY 9400615202 1016037643 1156026922

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 202 9400615202

ZEXEL 101603-7643 1016037643

ISUZU 1156026922 1156026922

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Buy INJECTION-PUMP ASSEMBLY 101603-7643 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7643 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6000

3. GOVERNOR 105931-8271

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105644-0470

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4521

11. Nozzle and Holder 1-15300-213-1

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

13. NOZZLE-HOLDER 105038-4001

14. NOZZLE

105017-0400

15. NOZZLE SET

Include in #1:

101603-7643 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1861 as _

Cross reference number

BOSCH 9 400 615 202 9400615202

ZEXEL 101603-7643 1016037643

ISUZU 1156026922 1156026922

Zexel num

Bosch num

Firm num

Name

101603-7643

9 400 615 202

1156026922 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-S 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)
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
After adjusting injection quantity. 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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 72.2 70.6 73.8

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 275 275 275

Average injection quantity mm3/st. 9.1 7.8 10.4

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)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 72.2 71.2 73.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 87.1 83.1 91.1

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 98 98 130

Fixing the lever *

Timer adjustment

Pump speed r/min 1275--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1225

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1275

Advance angle deg. 0.5

Load 4/4

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

Load 4/4

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=F89
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=29deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-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=131153-6420 ST=A743 L1=1mm L2=3.6+-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=8deg
----------
a=(60deg)

Information:

Caterpillar: Confidential Yellow
PARTS STOCK ACTION ONLY - THE DEFLECTOR SHIELDS ON CERTAIN UNIT INJECTORS IN PARTS STOCK MAY FAIL - PI7278 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, MARINE TEPS - REVISED 04/92
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.
March 6, 1992 (Revised April 1992) U-41 A-29 AU-24 B-19 E-23 O-37 TM-3 PARTS STOCK THE DEFLECTOR SHIELDS ON CERTAIN UNIT ACTION ONLY INJECTORS IN PARTS STOCK MAY FAIL 1290 PI7278 This Revised Service Letter replaces the March 6, 1992 Service Letter. Changes have been made to the injector group part numbers listed under Action Required. Termination Date
June 30, 1992
Problem
The deflector shields on certain unit injectors in parts stock may fail. All unit injectors in parts stock need to be inspected for the date code "BO".
Action Required
Remove all of