101603-7821 ZEXEL 9 400 615 217 BOSCH INJECTION-PUMP ASSEMBLY 9400615217 1016037821 1156027931

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 217 9400615217

ZEXEL 101603-7821 1016037821

ISUZU 1156027931 1156027931

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Buy INJECTION-PUMP ASSEMBLY 101603-7821 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7821 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4941

3. GOVERNOR 105931-8750

4. SUPPLY PUMP 105220-5970

5. AUTOM. ADVANCE MECHANIS 105644-0450

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:

101492-0570 as _

101603-7821 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 217 9400615217

ZEXEL 101603-7821 1016037821

ISUZU 1156027931 1156027931

Zexel num

Bosch num

Firm num

Name

101603-7821

9 400 615 217

1156027931 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TC2 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 4.9 4.85 4.95

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

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87.7 86.1 89.3

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)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87.7 86.7 88.7

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 95.5 92.3 98.7

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 5)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 72.8 69.6 76

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_06

Adjusting point D

Rack position R2-1.35

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. 96 96 128

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 R2-1.35

Boost pressure kPa 4 4 6.7

Boost pressure mmHg 30 30 50

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 5)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3 2.5 3.5

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. (3)Boost compensator stroke: BCL
----------
T1=F37 BCL=1.35+-0.1mm
----------

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=39.5deg+-5deg b=39deg+-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=131153-5520 ST=A734 L1=1mm L2=4.9+-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=11deg
----------
a=(60deg)

Information:

ACTION REQUIRED
See the attached Rework Procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Service Claim Allowances for Inspection
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
0 1 0 0 0 0
Service Claim Allowances for Replacement of the Filter Housing (if required)
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 1 0 0 0 0
Note: This is a 2-hour job if replacement is necessary.
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)
(2-Rework Procedure)
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
Safety - THE SPIN ON FUEL FILTER BASE NEEDS TO BE INSPECTED
MODELS INVOLVED - CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B DIESEL STANDBY ENGINES
Dear Caterpillar Product Owner:
The spin-on fuel filter base needs to be inspected on the products listed below. The stud height may be incorrect which can cause the spin-on fuel filter to blow off of the filter base and result in a fuel leakage hazard. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated November 23, 2000 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.
Caterpillar Inc.
Identification #(s)
Attached to November 23, 2000 Service Letter
Rework Procedure
Verification of Stud Height
Shut off the fuel supply to the engine.
Before removing the fuel filter, have a container ready to catch the fuel that will drain from the fuel system.
Remove the "Spin On" Fuel Filter. A filter wrench may be required.
Keep the fuel filter as it will be required for re-installation.
Measure the threaded nipple from the flat surface on the bottom of the filter base to the end of the nipple. See Illustration #1
Illustration #1
Check the stud height measurement from step #5 with Table #1
Table #1 - Stud Height Measurement
Acceptable Unacceptable
Stud Height 23.3 mm & up Less than 23.3 mm
If the stud height is falls in the "Unacceptable" Range, the fuel filter base must be replaced. See fuel filter base replacement instructions.
If the stud height is falls in the "Acceptable" range, the fuel filter should be reinstalled.
Return fuel flow to the engine.
Start the engine and check for leaks.
Replacement of 1N3789 Fuel Filter Base
Remove the fuel priming pump or cover from the base.
Loosen the fuel lines flowing into and out of the filter base.
Remove the fuel line adapters and the sensor (or plug) from the filter base before removing the filter base from the engine.
Remove the two mounts bolts, nuts and washers that mount the filter base. The filter base can then be removed.
Install a new 1N3789 Fuel Filter Base. Using the existing bolts, nuts and washers.
Note: The old 1N3789 Fuel Filter Base is not repairable and must be scrapped.
Reinstall the fuel line adapters and the sensor (or plug) with a new 3J1907 (adapters) and 6V5048 (sensor/plug) O-ring seals.
Reinstall the fuel lines.
Re-install the fuel priming pump or cover with new 9Y8589 and 9Y6094