Information injection-pump assembly
BOSCH
9 400 614 877
9400614877
ZEXEL
101602-7100
1016027100
ISUZU
1156023900
1156023900
Rating:
Service parts 101602-7100 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-105-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101602-7100
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1110
as _
Cross reference number
BOSCH
9 400 614 877
9400614877
ZEXEL
101602-7100
1016027100
ISUZU
1156023900
1156023900
Zexel num
Bosch num
Firm num
Name
101602-7100
9 400 614 877
1156023900 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
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
3.4
3.35
3.45
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
8.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
75.2
73.7
76.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.9+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
9.8
8.5
11.1
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)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=13 N1=1100r/min N2=850r/min
----------
----------
K=13 N1=1100r/min N2=850r/min
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
(1)Stopper bolt setting
----------
----------
a=17deg+-1deg b=20deg+-3deg c=19deg+-5deg
----------
----------
a=17deg+-1deg b=20deg+-3deg c=19deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
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) in the center of the elongated hole.
(3)Set the dead point position temporarily and measure the lever angle.
(4)Fix the lever (A) at the idle lever angle position using the bolt (E).
(5)Lock using bolt (G).
(6)After completing idle adjustment, loosen the full side stopper bolt (D).
(7)Move the lever (A) in the full speed direction.
(8)Fix bolt (D) at full speed position.
(9)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=14deg
----------
a=(100deg)
----------
aa=14deg
----------
a=(100deg)
Information:
ACTION REQUIRED
If your engine is experiencing a lack of power and/or black smoke emissions, complete the following action:
- Replace the six fuel injectors at the time of repair
Refer to KENR8106, Disassembly and Assembly, for removal/install procedure of the fuel injector groups.
It is recommended that REBE8794 be performed at the same time as REBE8786.
Refer to REHS7468, Special Instruction, "Procedure to Replace Fuel Filters in Certain 320D and 323D Excavators and Mobile Hydraulic Power Units", for the Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 33.0% 25.0% 33.0% 25.0% 34.0%
This is a 4.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 33.0% 25.0% 33.0% 25.0% 34.0%
This is a 4.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101602-7100?
Group cross 101602-7100 ZEXEL
Isuzu
101602-7100
9 400 614 877
1156023900
INJECTION-PUMP ASSEMBLY
6BD1T
6BD1T