101602-8340 ZEXEL 9 400 610 621 BOSCH INJECTION-PUMP ASSEMBLY 9400610621 1016028340 1156031590

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 621 9400610621

ZEXEL 101602-8340 1016028340

ISUZU 1156031590 1156031590

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Buy INJECTION-PUMP ASSEMBLY 101602-8340 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-8340 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6460

3. GOVERNOR 105419-2410

4. SUPPLY PUMP 105220-6300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

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:

101602-8340 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6130 as _

Cross reference number

BOSCH 9 400 610 621 9400610621

ZEXEL 101602-8340 1016028340

ISUZU 1156031590 1156031590

Zexel num

Bosch num

Firm num

Name

101602-8340

9 400 610 621

1156031590 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 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 8.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 59.5 58 61

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 375 375 375

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. 105 100 110

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
----------
K=8
----------

Speed control lever angle

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

----------
a=1deg+-5deg b=13deg+-5deg

Stop lever angle

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

----------
a=46deg+-5deg b=52deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(10deg)

Information:

Machine Specs.
Is stallcondition repeatable Can dealer reproduce?
WaterSeparator / Filter Does the Water Separator / Filter have water in it andwhat is the amount?
Is thegovernor assembly free to operate? Inspect pedal and cables for properoperation and no signs of significant wear or binding
Lowidle speed (no load) rpm
Highidle speed (no load) rpm
Torqueconverter stall speed (engine rpm) Record engine rpm as per RENR3574 Test& Adjust, Transmission and Torque converter testDirect Drive Transmission Arrangement
HP Rating Stall RPM 75 hp 1975 75 RPM 80 hp 2050 75 RPM 85 hp 2075 75 RPM 93 hp 2160 75 RPM Auto shift Transmission Arrangement
HP Rating Stall RPM 75 hp 2068 75 RPM 81 hp 2164 75RPM 90 hp 2206 75 RPM 98 hp 2218 75 RPM Note: Stall speeds are calculated usingNo. 2 diesel fuel.
Turboboost pressure at torque converter stall(full load boost spec is 82 - 85 kPa)
CoolantTemperature (at torque converter stall based on gage reading)
Smokecolor during torque converter stall test (if any) Is the smoke Black, Blue,White or none visible
HydraulicPump Test and Adjust RENR3584 Check for correct system pressure and torquelimiter settings. (Note: this step may be skipped if the dealer can confirmthat the hydraulic system has not been tampered with ? factory settingsare intact.)
Test235-1790 switch for proper operation. Cold advance for FIP, switch openscircuit when the coolant temp reaches 37-43 deg. C and closes at 27-33deg C.
"Wiggle"check electrical connections to and from FIP shutoff solenoid, cold startadvance, and electric lift pump circuit.
Machine Condition
Restrictionsin induction system present Check condition of Air filter and for debrisin the air pre-cleaner.
Restrictionsin exhaust system present?
Blockedfuel tank vent (fuel filler cap)
FuelSystem
SpecificChecks/Tests required Response
Fueltank temperature during either stall condition.
Checkfuel connections, fittings and clips. Check for looseness or fuel leakage.
Lowpressure fuel line interference conditions / restrictions (I.e. check routingof low pressure fuel line). Reference Service Magazine article on low pressurefuel system checks dated 23 Jun 2003.
Aeration(air present in fuel) See RENR2415 Test & Adjust. Air in Fuel ? Test(See illustration 1 for proper installation of clear tube on fuel injectionpump return line).
Fuelflow (low pressure fuel system) See RENR2415 Test & Adjust. Fuel SystemPressure- Test
Doesthe engine perform OK from a separate feed to the FIP? (Suspending a cleancontainer of clean fuel to gravity feed the FIP or fixing a slave liftpump directly to the FIP would eliminate the low pressure circuit on themachine)
Whatwas done to overcome the problem? Illustration 1