101602-8540 ZEXEL 9 400 614 943 BOSCH INJECTION-PUMP ASSEMBLY 9400614943 1016028540 1156032800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 943 9400614943

ZEXEL 101602-8540 1016028540

ISUZU 1156032800 1156032800

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Buy INJECTION-PUMP ASSEMBLY 101602-8540 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-8540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8880

3. GOVERNOR 105419-3050

4. SUPPLY PUMP 105220-7260

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 115300-291-2

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101602-8540 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6250 as _

Cross reference number

BOSCH 9 400 614 943 9400614943

ZEXEL 101602-8540 1016028540

ISUZU 1156032800 1156032800

Zexel num

Bosch num

Firm num

Name

101602-8540

9 400 614 943

1156032800 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 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=19deg+-5deg b=53deg+-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:

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
Bearing Driver(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.(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.Engine Inspection Record Sheet
1. Measurement of Cylinder Bore Diameter2. Measurement of Clearance between Valve Stem and Valve Guide, and Valve Stem Diameter3. Measurement of Valve Sinkage, Seat Width and Valve Margin4. Measurement of Distortion of Cylinder Head Bottom Surfaces5. Measurement of Oil Clearance of Connecting Rod Bearing6. Measurement of Rocker Arm Inside Diameter and Shaft Diameter7. Measurement of Piston Pin Bore Diameter and Piston Pin Diameter8. Measurement of Valve Clearance9. Measurement of Injection Pressure of Fuel Injection Nozzle10. Measurement of Clearance between Camshaft Journal Bore Diameter and Camshaft Bushing11. Measurement of Crankshaft End PlayEngine Inspection Record Sheet No. 1 Engine Inspection Record Sheet No. 2 Engine Inspection Record Sheet No. 3 Engine Inspection Record Sheet No. 4 Engine Inspection Record Sheet No. 5 Engine Inspection Record Sheet No. 6 Engine Inspection Record Sheet No. 7 Engine Inspection Record Sheet No. 8 Engine Inspection Record Sheet No. 9 Engine Inspection Record Sheet No. 10 Engine Inspection Record Sheet No. 11