101602-7711 ZEXEL 9 400 610 587 BOSCH INJECTION-PUMP ASSEMBLY 9400610587 1016027711 1156029910

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 587 9400610587

ZEXEL 101602-7711 1016027711

ISUZU 1156029910 1156029910

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Service parts 101602-7711 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4080

3. GOVERNOR 105419-1650

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5401

11. Nozzle and Holder 1-15300-196-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101401-0810 as _

101602-7711 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 587 9400610587

ZEXEL 101602-7711 1016027711

ISUZU 1156029910 1156029910

Zexel num

Bosch num

Firm num

Name

101602-7711

9 400 610 587

1156029910 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 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

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 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.4 47.9 50.9

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 400 400 400

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.

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=12 N1=1000r/min N2=800r/min
----------

Speed control lever angle

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

----------
a=(1deg)+-5deg b=(17deg)+-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 coupling's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(10deg)

Information:

Fuel Filter
Disassembly and Inspection of Fuel Filter
(For in-line fuel injection pump) (For distributor-type fuel injection pump) Reassembly of Fuel Filter
(For in-line fuel injection pump) Before installing the cartridge, clean the mounting surface on the cartridge, coat the gasket with clean fuel oil. Screw in the cartridge until the gasket contacts the seal surface of the bracket, then turn cartridge full turn by hand. (Do not use a filter wrench for this installation.) Do not use a filter that has dents or scratches, since damaged filter can break during engine operation.
After installation, start the engine and check to make sure there is no fuel leak.
(For distributor-type fuel injection pump) Do not use a filter that has dents or scratches, since damaged filter can break during engine operation.
After installation, start the engine and check to make sure there is no fuel leak.
Fuel Injection Nozzles
Disassembly of Fuel Injection Nozzles
Inspection of Fuel Injection Nozzles
Check each fuel injection nozzle for the following, and if defects are found, repair or replace the fuel injection nozzle.(1) Inspection of injection start pressure(a) Install each fuel injection nozzle on the nozzle tester, and move the handle up and down to release air.(b) Operate the handle of the tester at a rate of about 1 stroke per second, and read the indication on the pressure gage. The indication rises slowly, and the indicator oscillates during spraying. To obtain the injection start pressure value, read the indication when the indicator starts to oscillate.
Inspection of fuel injection nozzle valve opening(c) If the injection start pressure deviates significantly from the standard value, disassemble the fuel injection nozzle, and make an adjustment by changing the washer thickness. 0.1 mm [0.0039 in.] thickness of shims will change the injection pressure 0.98 Mpa (10 kgf/cm2 [142 psi]. The shims are available in 10 different thickness from 1.25 to 1.70 mm [0.0492 to 0.0669 in.] increment of 0.05 mm [0.0020 in.]
Never tap the tip of the nozzle tip when removing the nozzle tip.
Replacement of fuel injection nozzle tip(2) Inspection of fuel injection nozzle spray pattern(a) When inspecting each fuel injection nozzle with the nozzle tester, also check the nozzle for clogs, spray pattern and leakage.(b) Make sure that the fuel is sprayed straight from the nozzle when the handle of the tester is operated at a rate of about 1 stroke per second.
Inspection of spray pattern of fuel injection nozzle(3) Cleaning and replacement of faulty nozzles(a) Loosen the nozzle retaining nut, remove the nozzle tip, and clean the needle valve and body.
Never tap the tip of the nozzle tip when removing the nozzle tip.
(b) Use a fresh cleaning solution to clean the needle valve and body. After cleaning, assemble the needle valve and body in clean diesel fuel. The needle valve and body are precision finished. Handle them carefully, and do not change the combination of parts.
Cleaning of fuel injection nozzle tip(c) Tighten the nozzle retaining nut on the nozzle tip to the specified torque.(d) If the spray pattern is still not acceptable after adjustment