101602-7760 ZEXEL 9 400 610 592 BOSCH INJECTION-PUMP ASSEMBLY 9400610592 1016027760 1156030520

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 592 9400610592

ZEXEL 101602-7760 1016027760

ISUZU 1156030520 1156030520

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Buy INJECTION-PUMP ASSEMBLY 101602-7760 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-7760 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6410

3. GOVERNOR 105411-1580

4. SUPPLY PUMP 105220-5220

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156639-0420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6081

11. Nozzle and Holder 1-15300-247-1

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-8210

15. NOZZLE SET

Include in #1:

101602-7760 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1680 as _

Cross reference number

BOSCH 9 400 610 592 9400610592

ZEXEL 101602-7760 1016027760

ISUZU 1156030520 1156030520

Zexel num

Bosch num

Firm num

Name

101602-7760

9 400 610 592

1156030520 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T K 14BF INJECTION PUMP ASSY PE6AD 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 10.5

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 86.3 84.8 87.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point C

Rack position 7.3+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.8 9.5 12.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 10.2

Boost pressure kPa 9.3 6.6 12

Boost pressure mmHg 70 50 90

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.7

Boost pressure kPa 21.3 16 26.6

Boost pressure mmHg 160 120 200

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)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=8 BCL=0.5+-0.1mm N1=1050r/min N2=850r/min
----------

Speed control lever angle

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

----------
a=0deg+-5deg b=21deg+-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)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(20deg)

Information:

Disassembly and Reassembly of General Parts
Oil seals
When installing oil seals, observe the following.Installation of Oil Seals to Housings
(a) Check the seal lip for scratches and damage, and be sure to position the lip correctly.(b) Apply a small amount of grease to the periphery (housing contact surface) of the oil seal before installation.(c) Use an oil seal driver that guides the seal lip and presses the seal periphery, as shown in the diagram on the right. Striking the oil seal directly with a hammer causes seal damage and results in oil leaks.
Oil seal driverInstallation of Oil Seals to Shafts
(a) Apply grease to the oil seal lip.(b) Use an oil seal guide similar to the one shown in the diagram when installing an oil seal over the stepped portion, splines, threads or key grooves.
Oil seal guideO-rings
Use an O-ring guide similar to the one shown in the diagram when installing an O-ring over the stepped portion, splines, threads or key grooves. Be sure to apply a small amount of grease to the O-ring before installation.
O-ring guideBearings
(1) When installing a bearing, be sure to push the inner or outer race that fits into the installation position. (When the inner race fits into the installation position, push the inner race into position. When the outer race fits into the installation position, push the outer race into position.) Be sure to use a bearing driver similar to the one shown in the diagram.
Bearing driver(2) Use of a press minimizes the impact on the bearing and ensures proper installation.
Using press for bearing installationLock Plates
Be sure to bend lock plates. The diagram on the right shows the methods of bending representative lock plates.
Bending lock plateSplit Pins and Spring Pins
Generally, new split pins should be installed whenever split pins are removed. Be sure to bend split pins. Be sure to check spring pins for secure installation.