Information injection-pump assembly
BOSCH
9 400 614 872
9400614872
ZEXEL
101602-7050
1016027050
ISUZU
1156023750
1156023750
Rating:
Service parts 101602-7050 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
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:
101602-7050
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1131
as _
Cross reference number
BOSCH
9 400 614 872
9400614872
ZEXEL
101602-7050
1016027050
ISUZU
1156023750
1156023750
Zexel num
Bosch num
Firm num
Name
101602-7050
9 400 614 872
1156023750 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 * K 14BE PE6A PE
6BG1 * K 14BE 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
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
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
3.6
3.55
3.65
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
9.2
Pump speed
r/min
1175
1175
1175
Average injection quantity
mm3/st.
58.1
56.6
59.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.6
9.4
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
(4)Rack difference between N = N1 and N = N2
----------
K=14 N1=1175r/min N2=750r/min
----------
----------
K=14 N1=1175r/min N2=750r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-1deg b=(21deg)+-5deg
----------
----------
a=18deg+-1deg b=(21deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-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 flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
PARTS NEEDED
Qty
Part Number Description
1 2744962 PUMP GP-F INJ -B
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Replace the failed fuel injection pump. Refer to the engine's Disassembly and Assembly.
While carrying out "Fuel Injection Pump - Remove", please ensure that the fuel injection pump gear backlash is removed and the fuel injection pump locking bolt is tightened to a torque of 17 N.m (13 lb ft).
Fuel injection pumps that have not been locked correctly will have the claim rejected or debited.
After the new fuel injection pump has been installed, carry out checks for air in the fuel. Refer to the engine's Testing and Adjusting, "Air in Fuel - Test".
To ensure correct priming of the fuel system on first start-up, follow the procedure below.
1. Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly.
2. Set the throttle to the low idle position and ensure the parking brake is engaged
3. Crank the engine for 1 second to initiate the fuel priming sequence (do not start the engine)
4. Return ignition switch to the RUN position & listen for the fuel priming pump running
5. Leave the ignition key in the RUN position for three minutes.
6. Crank the engine with the throttle lever in the CLOSED position until the engine starts.
7. Run the engine at low idle for one minute.
8. Cycle the throttle lever from the low idle position to the high idle position three times. The cycle time for the throttle lever is one second to six seconds for one complete cycle.
9. Check for leaks in the fuel system.
Documentation Procedure
Please ensure that when submitting the claim the following documentation is provided.
1. Full details of the customer?s complaint and the symptoms witnessed.
2. Test work and diagnostic checks carried out to diagnose that the fuel injection pump is the part causing failure.
3. Results from the Testing and Adjusting, "Air in Fuel - Test". Please include photos of any air seen in the SIMS entry.
If the requested documentation is not provided, the claim may be rejected or debited.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
Refer to the Documentation Procedure in the Action Required for the Service Claim.
PARTS DISPOSITION
***** NACD *****
Hold all failed fuel injection pumps for a Parts Return Request (PRR). A PRR will be issued to you through the Send-It-Back process after the claim is submitted. Make
Have questions with 101602-7050?
Group cross 101602-7050 ZEXEL
Isuzu
101602-7050
9 400 614 872
1156023750
INJECTION-PUMP ASSEMBLY
6BG1
6BG1