101685-0380 ZEXEL 9 400 610 144 BOSCH INJECTION-PUMP ASSEMBLY 9400610144 1016850380 1156002601

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 144 9400610144

ZEXEL 101685-0380 1016850380

ISUZU 1156002601 1156002601

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Buy INJECTION-PUMP ASSEMBLY 101685-0380 zexel genuine, new aftermarket engine parts with delivery

Service parts 101685-0380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101068-3640

3. GOVERNOR 105410-2710

4. SUPPLY PUMP 105210-6000

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-2010

11. Nozzle and Holder 9-15300-184-2

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105031-2600

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101685-0380 as INJECTION-PUMP ASSEMBLY

Include in #2:

104745-3430 as _

104745-3431

104745-3432

Cross reference number

BOSCH 9 400 610 144 9400610144

ZEXEL 101685-0380 1016850380

ISUZU 1156002601 1156002601

Zexel num

Bosch num

Firm num

Name

101685-0380

9 400 610 144

1156002601 ISUZU

INJECTION-PUMP ASSEMBLY
DA640 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

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 1-4-2-6- 3-5

Pre-stroke mm 2.2 2.15 2.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 13.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 65.5 64.1 66.9

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.7

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 60 57.8 62.2

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 12.1

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 53 51.2 54.8

Max. variation between cylinders % 0 -3 3

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 10+-5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 8.7 13.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

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)At rack cap installation: R1
----------
K=10 R1=(17.5)mm
----------

Speed control lever angle

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

----------
a=16.5deg+-5deg b=32deg+-5deg c=32deg+-3deg

Information:

2. Remove two short bolts (1) and two longer bolts (2) from manifold (3) and BrakeSaver housing.3. Remove the manifold from the control valve. 4. Remove the three bolts from elbows (5) and the control valve.5. Remove four bolts (4) that hold the control valve to the oil pan.6. Remove the control valve from under the oil pan.7. Make an inspection of the O-ring seals on the manifold and on the control valve. If there is wear or damage make a replacement of the O-ring seals.Install Brakesaver Control Valve
1. Put clean SAE 30 engine oil on O-ring seals (1).2. Put the control valve in position under the oil pan. Install the four bolts that hold the control valve to the oil pan.3. Install the elbow and the bolts that hold it to the side of the control valve. 4. Put SAE 30 engine oil on the O-ring seals of the manifold. Install manifold (2) in the control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.5. Fill the engine with oil. See 3408 TRUCK ENGINE LUBRICATION AND MAINTENANCE GUIDE.Disassemble Brakesaver Control Valve
start by:a) remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.
Spring force is behind the cover at removal.
3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the plate valve with the pin on the spool. Install the bolt that holds the plate and the diaphragm in position.
When diaphragm (4) is installed on valve spool (3), make sure the fabric side is pulled down over the valve spool to make contact with it and the smooth (rubber coated) side is next to valve body.
2. Install sleeves (1) and the seals in the valve body. 3. Install the valve spool as an assembly into the valve body. As the valve spool is installed, make sure the edge of the diaphragm makes contact all the way around with the groove in the valve body. At this time the valve spool end must extend about 1.50 in. (38.1 mm) from the valve body. Push the valve spool about .25 in. (6.4 mm) - .50 in. (12.7 mm) farther into the valve body until a curved depression is caused between the valve spool and valve body. Make sure there are no wrinkles in the diaphragm. 4. Put cover (9) in position. Install the four bolts that hold the cover on the valve body. Move the valve spool in the