101602-4620 ZEXEL 9 400 614 845 BOSCH INJECTION-PUMP ASSEMBLY 9400614845 1016024620 1156021040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 845 9400614845

ZEXEL 101602-4620 1016024620

ISUZU 1156021040 1156021040

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Buy INJECTION-PUMP ASSEMBLY 101602-4620 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-4620 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4300

3. GOVERNOR 105410-8420

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0691

7. COUPLING PLATE 156637-0020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

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

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101602-4620 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-1370 as _

Cross reference number

BOSCH 9 400 614 845 9400614845

ZEXEL 101602-4620 1016024620

ISUZU 1156021040 1156021040

Zexel num

Bosch num

Firm num

Name

101602-4620

9 400 614 845

1156021040 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE 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 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

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 8.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 56.5 55 58

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 58.8 56.8 60.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point -

Rack position 6.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.4 8 10.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=5
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=33deg+-5deg

Stop lever angle

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

----------
a=12deg+-5deg b=46deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Removing And Fitting A Starter Gear Ring
It is assumed that the flywheel is dismantled.Removing:
6-1Cut through the starter gear ring with a hard chisel and remove.Fig. 6-1Refitting:
1. Heat the starter gear ring to a temperature of 120 deg. C. Place the starter gear ring with the bevelled side of the teeth facing away from flywheel.
6-22. Locate the starter gear ring on the flywheel and tap it into position so that it seats against the shoulder.Fig. 6-2Removing And Fitting A Radial Sealing Ring On The Flywheel Side
It is assumed that the flywheel has been dismantled. Removing:
6-3Apply puller No. 142700 and draw off radial sealing ring.Fig. 6-3Refitting:
6-41. Mount guide-piece of device onto crankshaft.Fig. 6-4
6-52. Lightly grease the sealing lip of the new radial seal. Place seal on guide-piece with lip facing towards crankcase and press in with device No. 142530.Fig. 6-5 Inspect crankshaft in the zone of radial seal contact. If a friction groove has been formed by the radial seal, displace the complete cover by adding gaskets accordingly.Dismantling, Installing And Sealing The Cover On The Flywheel Side (As from 3-cylinder engine)
The flywheel has already been removed.Dismantling:
1. Remove the bolts in the oil sump securing the cover on the flywheel side and the bolts securing the cover to the crankcase. Remove cover and gasket. Renew radial sealing ring. Inspect crankshaft in the zone of radial seal contact. If a friction groove has been formed by the radial seal, displace the latter in the cover.Installing:
6-112. Adhere new gasket to crankcase. Trim off the portion of gasket projecting beyond the joint surface of the sump. Fig. 6-113. Apply coat of Deutz DW 48 jointing compound to the oil sump gasket in the region of the cover.
6-124. Press new radial seal into the rear cover so that the outside surface is flush (arrow).Fig. 6-12 Prior to fitting, heat cover "hand-warm" and coat radial seal with jointing compound.
6-135. Place cover in position. Lightly pretighten cover bolts in crankcase. Fully tighten sump bolts in cover, then fully tighten bolts in crankcase.Fig. 6-13Exploded Views