Information injection-pump assembly
BOSCH
9 400 612 612
9400612612
ZEXEL
101602-4281
1016024281
ISUZU
1156017341
1156017341

Rating:
Service parts 101602-4281 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-104-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101602-4281
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-5530
as _
Cross reference number
BOSCH
9 400 612 612
9400612612
ZEXEL
101602-4281
1016024281
ISUZU
1156017341
1156017341
Zexel num
Bosch num
Firm num
Name
101602-4281
9 400 612 612
1156017341 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T K 14BE INJECTION PUMP ASSY PE6A PE
6BD1T K 14BE INJECTION PUMP ASSY PE6A PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
68.4
66.9
69.9
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.6+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10.2
8.9
11.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle

F:Full speed
I:Idle
D:Dead point
(1)Set the pump speed at aa
(2)Set the pump speed at bb (at delivery)
(3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=5deg+-5deg c=17deg+-3deg d=26deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=5deg+-5deg c=17deg+-3deg d=26deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=2.5deg+-5deg b=46deg+-5deg
----------
----------
a=2.5deg+-5deg b=46deg+-5deg
0000001501 LEVER

1. Variable lever adjustment
(1)Fix lever (B) in the idle position using bolts (C) and (D).
(2)Temporarily fix the lever (A) at the dead point and measure the lever angle .
(3)Fix the lever (A) at the idle lever angle position using the bolt (E).
(4)Lock using bolt (G).
(5)After completing idle adjustment, loosen the full side stopper bolt (D).
(6)Move the lever (A) in the full speed direction.
(7)Fix bolt (D) at full speed position.
(8)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------
----------
----------
----------
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(90deg)
----------
aa=16deg
----------
a=(90deg)
Information:
Fluids/Filters Recommendation
Literature InformationThis manual should be stored in the literature holder or in the literature storage area on the machine. Immediately replace this manual if lost, damaged, or unreadable.The information contained in this document is the most current information available for fluid maintenance and service products. Special maintenance and service products may be required for some machine compartments. Refer to the Operation and Maintenance Manual for your machine for the maintenance and service requirements. Read, study, and keep this manual with the product. This manual should be read carefully before using this product for the first time and before performing maintenance.Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.SafetyRefer to the Operation and Maintenance Manual for your machine for all safety information. Read and understand the basic safety precautions listed in the Safety Section. In addition to safety precautions, this section identifies the text and locations of warning signs used on the machine.Read and understand the applicable precautions listed in the Maintenance and Operation Sections before operating or performing lubrication, maintenance, and repair on this machine.MaintenanceRefer to the Operation and Maintenance Manual for your machine to determine all maintenance requirements.Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.Maintenance Interval ScheduleUse the Maintenance Interval Schedule in the Operation and Maintenance Manual for your machine to determine servicing intervals. Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if calendar intervals provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.Under extremely severe, dusty, or wet operating conditions, more frequent lubrication and/or filter changes than is specified in the maintenance intervals chart might be necessary.Following the recommended maintenance intervals reduces the risk of excessive wear and potential failures of components.Aftermarket Products and Warranty
When auxiliary devices, accessories or consumables (filters, oil, additives, catalysts, fuel, etc.) made by other manufacturers are used on Cat products, the Caterpillar warranty is not affected simply because of such use. Failures that result from the installation or usage of other manufacturers auxiliary devices, accessories or consumables, however, are not Caterpillar factory defects and therefore are NOT covered by Caterpillar's warranty.Caterpillar is not in a position to evaluate the many auxiliary devices, accessories or consumables promoted by other manufacturers and their effect on Cat products. Installation or use of such items is at the discretion of the customer who assumes ALL risks for the effects that result from this usage.Furthermore, Caterpillar does not authorize the use of its trade name, trademark, or logo in a manner which implies our endorsement of these aftermarket products.
Literature InformationThis manual should be stored in the literature holder or in the literature storage area on the machine. Immediately replace this manual if lost, damaged, or unreadable.The information contained in this document is the most current information available for fluid maintenance and service products. Special maintenance and service products may be required for some machine compartments. Refer to the Operation and Maintenance Manual for your machine for the maintenance and service requirements. Read, study, and keep this manual with the product. This manual should be read carefully before using this product for the first time and before performing maintenance.Whenever a question arises regarding your product, or this publication, consult your dealer for the latest available information.SafetyRefer to the Operation and Maintenance Manual for your machine for all safety information. Read and understand the basic safety precautions listed in the Safety Section. In addition to safety precautions, this section identifies the text and locations of warning signs used on the machine.Read and understand the applicable precautions listed in the Maintenance and Operation Sections before operating or performing lubrication, maintenance, and repair on this machine.MaintenanceRefer to the Operation and Maintenance Manual for your machine to determine all maintenance requirements.Proper maintenance and repair are essential to keep the equipment and systems operating correctly. As the owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.Maintenance Interval ScheduleUse the Maintenance Interval Schedule in the Operation and Maintenance Manual for your machine to determine servicing intervals. Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if calendar intervals provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs first.Under extremely severe, dusty, or wet operating conditions, more frequent lubrication and/or filter changes than is specified in the maintenance intervals chart might be necessary.Following the recommended maintenance intervals reduces the risk of excessive wear and potential failures of components.Aftermarket Products and Warranty
When auxiliary devices, accessories or consumables (filters, oil, additives, catalysts, fuel, etc.) made by other manufacturers are used on Cat products, the Caterpillar warranty is not affected simply because of such use. Failures that result from the installation or usage of other manufacturers auxiliary devices, accessories or consumables, however, are not Caterpillar factory defects and therefore are NOT covered by Caterpillar's warranty.Caterpillar is not in a position to evaluate the many auxiliary devices, accessories or consumables promoted by other manufacturers and their effect on Cat products. Installation or use of such items is at the discretion of the customer who assumes ALL risks for the effects that result from this usage.Furthermore, Caterpillar does not authorize the use of its trade name, trademark, or logo in a manner which implies our endorsement of these aftermarket products.
Have questions with 101602-4281?
Group cross 101602-4281 ZEXEL
Isuzu
101602-4281
9 400 612 612
1156017341
INJECTION-PUMP ASSEMBLY
6BD1T
6BD1T