101602-8351 ZEXEL 9 400 610 622 BOSCH INJECTION-PUMP ASSEMBLY 9400610622 1016028351 1156031971

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 622 9400610622

ZEXEL 101602-8351 1016028351

ISUZU 1156031971 1156031971

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Service parts 101602-8351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8130

3. GOVERNOR 105419-2491

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-0520

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:

101602-8351 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6132 as _

Cross reference number

BOSCH 9 400 610 622 9400610622

ZEXEL 101602-8351 1016028351

ISUZU 1156031971 1156031971

Zexel num

Bosch num

Firm num

Name

101602-8351

9 400 610 622

1156031971 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 9

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 71 69.5 72.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.9+-0.5

Pump speed r/min 500 500 500

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. 90 85 95

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=10
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Set the pump speed at aa (3)Set speed at bb (setting at delivery).
----------
aa=750r/min bb=900r/min
----------
a=3deg+-5deg b=15deg+-5deg c=5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=66.5deg+-5deg b=53deg+-5deg

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)

Information:

Refer to attached 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*******
0-2000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
2001-5000 hrs,
13-18 mo 100.0% 50.0% 0.0% 0.0% 0.0% 50.0%
5001-8000 hrs,
19-24 mo 100.0% 30.0% 0.0% 0.0% 0.0% 70.0%
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*******
0-2000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
2001-5000 hrs,
13-18 mo 100.0% 50.0% 0.0% 0.0% 0.0% 50.0%
5001-8000 hrs,
19-24 mo 100.0% 30.0% 0.0% 0.0% 0.0% 70.0%
This is a 4.0-hour job for Group 2
PARTS DISPOSITION
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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
For the following units listed remove (6) 207-5248 Injector Rocker Arms, and replace with (6) 278-1365 Injector Rocker Arms.
For proper ?Disassembly & Assembly? instructions of the injector rocker arms please refer to the following Publications in SIS Web. (SENR9832-06 Testing & Adjusting-Finding Top Dead Center Position for No. 1 Piston), (SENR9832-06 Testing & Adjusting-Electronic Unit Injector Adjusting & Setting), and (SENR9832-06 Testing & Adjusting-Engine Valve Lash Inspect/Adjust).
Note: It is important that while installing the 278-1365 Injector Rocker Arms, that the engine is in the proper position (Top Dead Center and 180 degrees out) so the Injector Rocker Arms are properly adjusted and set. It is also important that during the installation of the Injector Rocker Arms that the Exhaust Valve, and Intake Valve lash settings be inspected and if needed re-set to factory specifications.
Note: During the rework process please inspect the 6I-0901 Rocker Arm Shafts for any signs of misalignment of the stud mounting holes, wear, damage, fretting etc. If damage is found to the shaft or if fretting or damage is found with any of the through bolt/stud mounting holes, the shaft is to be replaced, and reported against this service letter as contingent damage.