101602-8330 ZEXEL 9 400 610 620 BOSCH INJECTION-PUMP ASSEMBLY 9400610620 1016028330 1156031370

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 620 9400610620

ZEXEL 101602-8330 1016028330

ISUZU 1156031370 1156031370

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Buy INJECTION-PUMP ASSEMBLY 101602-8330 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-8330 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6460

3. GOVERNOR 105419-2400

4. SUPPLY PUMP 105220-6300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6682

11. Nozzle and Holder 1-15300-291-2

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101401-0971 as _

101602-8330 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 620 9400610620

ZEXEL 101602-8330 1016028330

ISUZU 1156031370 1156031370

Zexel num

Bosch num

Firm num

Name

101602-8330

9 400 610 620

1156031370 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 K 14BE INJECTION PUMP ASSY PE6A PE

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

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 A

Rack position 8.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 59.5 58 61

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 105 100 110

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=8
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=1deg+-5deg b=13deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=46deg+-5deg b=52deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(10deg)

Information:

April 19, 2004
U-118
A-80
D-95
O-98
TT-10
TA-1
TM-3
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMANUFCTURED FUEL INJECTORS FROM DEALER PARTS STOCK
7750 PI70077
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
July 31, 2004PROBLEM
The injector nose cone may be undersize on certainremanufactured fuel injectors that are used in various 3116 Engines. All0R8461, 0R8463, 0R8465, 0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483,0R8633, 0R8682, 0R8684, and 0R8867 Remanufactured Fuel Injectors with DateCodes from 01/02/04 to 31/03/04 stamped on the box need to be removed fromdealer stock.ACTION REQUIRED
Remove all Remanufactured Fuel Injectors listedin the following chart from dealer parts stock that have Date Codes from01/02/04 to 31/03/04 stamped on the box.
Part Number Description Box Date Code
0R8461 INJECTOR GP 01/02/04 to 31/03/04
0R8463 INJECTOR GP 01/02/04 to 31/03/04
0R8465 INJECTOR GP 01/02/04 to 31/03/04
0R8469 INJECTOR GP 01/02/04 to 31/03/04
0R8471 INJECTOR GP 01/02/04 to 31/03/04
0R8473 INJECTOR GP 01/02/04 to 31/03/04
0R8475 INJECTOR GP 01/02/04 to 31/03/04
0R8479 INJECTOR GP 01/02/04 to 31/03/04
0R8483 INJECTOR GP 01/02/04 to 31/03/04
0R8633 INJECTOR GP 01/02/04 to 31/03/04
0R8682 INJECTOR GP 01/02/04 to 31/03/04
0R8684 INJECTOR GP 01/02/04 to 31/03/04
0R8867 INJECTOR GP 01/02/04 to 31/03/04
SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R8461, 0R8463, 0R8465,0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684,and 0R8867 Remanufactured Fuel Injectors that were removed from dealerparts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70077.***** All Dealers *****Return all 0R8461, 0R8463, 0R8465, 0R8469,0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684, and 0R8867Remanufactured Fuel Injectors that are removed from parts stock and a copyof the claim to:Caterpillar Inc.
Attn: Noe S. Perez - PI70077
Service Claims Room
8201 N. University
Peoria, IL 61615