101602-7810 ZEXEL 9 400 610 595 BOSCH INJECTION-PUMP ASSEMBLY 9400610595 1016027810 1156029690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 595 9400610595

ZEXEL 101602-7810 1016027810

ISUZU 1156029690 1156029690

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Buy INJECTION-PUMP ASSEMBLY 101602-7810 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-7810 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8880

3. GOVERNOR 105419-1860

4. SUPPLY PUMP 105220-6300

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:

101491-0420 as _

101602-7810 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 595 9400610595

ZEXEL 101602-7810 1016027810

ISUZU 1156029690 1156029690

Zexel num

Bosch num

Firm num

Name

101602-7810

9 400 610 595

1156029690 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T 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 1150 1150 1150

Average injection quantity mm3/st. 62.5 61 64

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.1+-0.5

Pump speed r/min 350 350 350

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. 85 80 90

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 (6)Rack difference between N = N1 and N = N2
----------
K=14 N1=1150r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=22deg+-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 gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(100deg)

Information:

Flywheel
Installation of Flywheel Housing
Installation of flywheel housing(1) Install the oil seal to the flywheel housing.(2) Coat the contact surfaces of the crankcase and flywheel with ThreeBond 1104.(3) Align the holes in the flywheel housing and gasket with the dowel pins on the crankcase, and install them to the crankcase.Installation of Flywheel
(1) Install the flywheel to the crankshaft by aligning the hole with the dowel pin on the back-end of the crankshaft.(2) Place the washer and tighten the four bolts to the specified torque.
Installation of flywheelMeasurement of Flywheel Runout
Measure the flywheel runout with the flywheel installed to the crankshaft. If the standard value is exceeded, check the bolts for tightening condition and the mounting face for adhesion of foreign particles.
Measurement of face runout and circular runoutCylinder Head and Valve Mechanisms
Installation of Valve Stem Seal
(1) Apply engine oil to the valve stem, and insert it into the valve guide.(2) Place a new stem seal on the valve guide.(3) Using the stem seal installer, install the stem seal to the valve guide, making use of the valve stem as a guide.
Installation of valve stem sealInstallation of Valves and Valve Springs
(1) Place the valve spring and retainer on the valve guide, and install the valve cotter using the valve spring pusher.
Excessive compression of the valve spring can cause the retainer to contact the stem seal and damage the seal.
Installation of valve and valve spring(2) Using a soft-faced hammer, tap the top of the valve stem several times to make sure that the spring and valve cotter are securely installed.
Confirmation of secure valve cotter installationInstallation of Cylinder Head Gasket
(1) Make sure that the top face of the crankcase and piston upper surfaces are clean and free of dust.(2) Place a new gasket of the crankcase, making sure that the dowel pins on the top face of the crankcase enter the holes in the gasket.
Do not use a liquid gasket.
Installation of cylinder head gasketInstallation of Cylinder Head
Place the cylinder head on the head gasket, making sure that the dowel pins on the top face of the crankcase enters the holes in the cylinder head.
Installation of cylinder head assemblyTightening of Cylinder Head Bolts
Tighten the cylinder head bolts, following the tightening sequence shown in the diagram two or three times before reaching the specified torque.
Cylinder head bolt tightening sequenceAssembly of Rocker Arm and Rocker Shaft Assembly
When installing the rocker arms, make sure that the shaft assembly marks face the front of the engine, as shown in the diagram. After the assembly, make sure that the rocker arms move smoothly.
Assembly of rocker shaft assemblyInstallation of Pushrods
(1) Insert the pushrods in the cylinder head through the pushrod holes.(2) Make sure that the ball end of each pushrod rests securely on the curved surface of the tappet.Installation of Rocker Shaft Assemblies
(1) Install the valve caps.(2) When installing the rocker shaft brackets, tighten the long bolts first, then tighten the short bolts (reversal of removal sequence).
Installation of rocker shaft assemblyAdjustment of Valve Clearances
(1) Confirming the top dead center on the