101603-7811 ZEXEL 9 400 615 216 BOSCH INJECTION-PUMP ASSEMBLY 9400615216 1016037811 1156027861


 

Information injection-pump assembly

BOSCH 9 400 615 216 9400615216
ZEXEL 101603-7811 1016037811
ISUZU 1156027861 1156027861
101603-7811 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101603-7811 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7811 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4881
3. GOVERNOR 105931-8740
4. SUPPLY PUMP 105220-5930
5. AUTOM. ADVANCE MECHANIS 105644-0440
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5095
11. Nozzle and Holder 1-15300-266-4
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3862
14. NOZZLE 105017-1111
15. NOZZLE SET

Include in #1:

101603-7811 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 216 9400615216
ZEXEL 101603-7811 1016037811
ISUZU 1156027861 1156027861


Zexel num
Bosch num
Firm num
Name
101603-7811 
9 400 615 216 
1156027861  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TC1 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
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   13.2
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.1 97.3
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.   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(13.2)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.7 96.7
Basic   *
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.15
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   96.7 93.5 99.9
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 55)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   77 73.8 80.2
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.5
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   54 50.8 57.2
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   93 93 125
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R2-1.5
Boost pressure kPa   3.3 3.3 6
Boost pressure mmHg   25 25 45
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   R2(R1-0. 55)
Boost pressure kPa   21.3 21.3 21.3
Boost pressure mmHg   160 160 160
Timer adjustment
Pump speed r/min   (1170)
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1325
Advance angle deg.   1.5 1 2
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7811
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F36 BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 101603-7811
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39.5deg+-5deg b=(37deg)+-3deg

Stop lever angle

Test data 101603-7811
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=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7811
(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=(60deg)




Information:

This Program must be administered as soon as possible. When reporting the repair, use "PI3325" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3325" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
February 29, 2000Termination Date
February 29, 2000Problem
Upgrade software needs to be installed on certain 3606, 3608, 3612, and 3616 diesel engines with the Marine Monitoring System (MMS) to become Y2K compatible.
Affected Product
Model & Identification Number
3606 (8RB29, 8RB656-661, 8RB669, 8RB672-673, 8RB680-688, 8RB691-00692, 8RB695-702, 8RB711-00713, 8RB715, 8RB717-718, 8RB721-723)
3608 (6MC535-536, 6MC550, 6MC561-562, 6MC582-586)
3612 (9RC230, 9RC242, 9RC247-253, 9RC256-257, 9RC259-260)
3616 (1PD289-293, 1PD295, 1PD306, 1PD308, 1PD313-336)
Parts Needed
- Dealers will need to obtain the Upgrade Files for this program.- 1 Blank formatted 1.44 MB floppy disk for Winfile Upgrade- 6 Blank formatted 1.44 MB floppy disks for InTouch 5.6B UpgradeAction Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This is a 1-hour job.
U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(1-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Windows 3.11 Winfile Upgrade
This upgrade is necessary for Windows 3.11 to correctly date stamp files after the year 2000, The first three steps in the following procedure will be done in the office or shop.
1. Obtain the file. The file can be obtained from the Caterpillar Mailbox, SISWEB, or from the SIS disks that are released monthly. The file part number is 174-8693.2. Unzip the file. The 174-8693.exe file is a self-executing zip file. To Unzip, place the file in a known location on the hard drive. Run the file. At the dialog box type in 'A:\' where it asks for the folder to place unzipped files. Install a blank formatted disk into the A: drive. Select UNZIP or press "ENTER". This will unzip the files to the floppy drive. If your floppy drive is not 'A:' substitute your floppy drive letter for A in the above instuctions.)
3. Label the disk. This disk should be labeled "Winfile.exe Y2K Upgrade". This disk or a copy of this disk can be used to do multiple upgrades. It is not necessary to repeat steps 1-3 for each upgrade.4. Perform the upgrade. The upgrade should be done from the DOS prompt. Attach a keyboard to the MMS computer. With the MMS program running press "ALT"and "F4" at the same time. This will exit the MMS program. Press "ALT"and "F4" at the same time again and you will get a dialog box that asks you to confirm you want to end your Windows session. Press "ENTER" to confirm. Install the floppy labeled "Winfile.exe Y2K Upgrade" into the floppy drive on the MMS

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Group cross 101603-7811 ZEXEL

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