Information injection-pump assembly
BOSCH
9 400 614 906
9400614906
ZEXEL
101602-7590
1016027590
ISUZU
1156028560
1156028560
Rating:
Service parts 101602-7590 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Include in #1:
101602-7590
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-1213
as _
Cross reference number
BOSCH
9 400 614 906
9400614906
ZEXEL
101602-7590
1016027590
ISUZU
1156028560
1156028560
Zexel num
Bosch num
Firm num
Name
101602-7590
9 400 614 906
1156028560 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE PE6A PE
6BD1 * 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
132424-0620
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
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
3.5
3.45
3.55
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
8.8
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
72.7
71.2
74.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.2
7.9
10.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
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
(2)Set idle sub-spring
(3)Main spring setting
----------
K=11
----------
----------
K=11
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(15deg)+-5deg b=(29deg)+-5deg
----------
----------
a=(15deg)+-5deg b=(29deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)
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=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
(5) Removing Alternator
(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loose the alternator adjusting bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator.
Removing alternator(6) Removing Starter
(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the starter wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3).
Removing starter(7) Removing Oil Filter
(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1).
Removing oil filter(8) Removing Fuel Filter
(a) Remove the fuel hose (1) that leads to the fuel injection pump.(b) Remove the fuel filter (2) from the engine.
Removing fuel filter(9) Removing Fuel Pipes
(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the lock nuts (2) and the fuel leak-off pipe (3) from the injection nozzle.
Removing Fuel Pipes
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
Removing Injection Pump(1) Fuel hose(2) Fuel pipe(3) Tie rod cover(4) Tie rod spring(5) Tie rod(6) Injection pump(7) Adjustment shim(8) Control rack pin(a) Remove the tie rod cover (3).(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing ETS Solenoid
Loose the nut (1) and remove the ETS solenoid (2).
Removing ETS solenoid(12) Removing Oil Pump
Remove the oil pump's four mounting bolts, then remove the oil pump (1).
Removing oil pump(13) Removing Injection Nozzle
(a) Remove all lock nuts (1) (4 pieces).(b) Remove fuel leak-off pipe (2) and fuel return gasket (3).(c) Remove fuel injection nozzle (4) and holder gasket (5).
Removing injection nozzleRefitting Accessories
General Points
Refit accessories by following the removal procedures in reverse. After refitting accessories, perform the following:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the coolant system.(3) To facilitate starting, pour engine oil into the governor's hydraulic oil filter via the hole of the air bleeding plug.(4) Make sure no oil or coolant is leaking from joints and connections.(5) Air-bleed the fuel system.(6) After refitting the injection pump (see the instructions below), be sure to inspect and adjust the injection timing.Installing Injection Pump
Installation should be performed basically by following the removal procedure in reverse. The following operations must also be performed.(1) Bleeding Air from Fuel System
Bleeding air from fuel system(a) Feed fuel to the engine by turning the key to the ON position. Then, loosen the air vent screw (1), allow air in the filter to be expelled, and retighten the screw.(b) Loosen air vent screws (2) and (3) on the injection pump in that sequence to bleed air from the
(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loose the alternator adjusting bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator.
Removing alternator(6) Removing Starter
(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the starter wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3).
Removing starter(7) Removing Oil Filter
(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1).
Removing oil filter(8) Removing Fuel Filter
(a) Remove the fuel hose (1) that leads to the fuel injection pump.(b) Remove the fuel filter (2) from the engine.
Removing fuel filter(9) Removing Fuel Pipes
(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the lock nuts (2) and the fuel leak-off pipe (3) from the injection nozzle.
Removing Fuel Pipes
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
Removing Injection Pump(1) Fuel hose(2) Fuel pipe(3) Tie rod cover(4) Tie rod spring(5) Tie rod(6) Injection pump(7) Adjustment shim(8) Control rack pin(a) Remove the tie rod cover (3).(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing ETS Solenoid
Loose the nut (1) and remove the ETS solenoid (2).
Removing ETS solenoid(12) Removing Oil Pump
Remove the oil pump's four mounting bolts, then remove the oil pump (1).
Removing oil pump(13) Removing Injection Nozzle
(a) Remove all lock nuts (1) (4 pieces).(b) Remove fuel leak-off pipe (2) and fuel return gasket (3).(c) Remove fuel injection nozzle (4) and holder gasket (5).
Removing injection nozzleRefitting Accessories
General Points
Refit accessories by following the removal procedures in reverse. After refitting accessories, perform the following:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the coolant system.(3) To facilitate starting, pour engine oil into the governor's hydraulic oil filter via the hole of the air bleeding plug.(4) Make sure no oil or coolant is leaking from joints and connections.(5) Air-bleed the fuel system.(6) After refitting the injection pump (see the instructions below), be sure to inspect and adjust the injection timing.Installing Injection Pump
Installation should be performed basically by following the removal procedure in reverse. The following operations must also be performed.(1) Bleeding Air from Fuel System
Bleeding air from fuel system(a) Feed fuel to the engine by turning the key to the ON position. Then, loosen the air vent screw (1), allow air in the filter to be expelled, and retighten the screw.(b) Loosen air vent screws (2) and (3) on the injection pump in that sequence to bleed air from the
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Group cross 101602-7590 ZEXEL
Isuzu
101602-7590
9 400 614 906
1156028560
INJECTION-PUMP ASSEMBLY
6BD1
6BD1