101602-0620 ZEXEL 9 400 610 143 BOSCH INJECTION-PUMP ASSEMBLY 9400610143 1016020620 1156009241

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 143 9400610143

ZEXEL 101602-0620 1016020620

ISUZU 1156009241 1156009241

Service parts 101602-0620 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2180

3. GOVERNOR 105411-0771

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

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

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101602-0620 as INJECTION-PUMP ASSEMBLY

101609-3370 as _

Cross reference number

BOSCH 9 400 610 143 9400610143

ZEXEL 101602-0620 1016020620

ISUZU 1156009241 1156009241

Zexel num

Bosch num

Firm num

Name

101602-0620

9 400 610 143

1156009241 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T * K 14BE 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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.4 3.35 3.45

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 8.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 77.1 75.1 79.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_02

Adjusting point B

Rack position 8.4

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 79.4 77.9 80.9

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_03

Adjusting point C

Rack position 8.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55.4 53.4 57.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position 5.2+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12.7 11.4 14

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position 9.2+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 58.2 58.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 8.1

Boost pressure kPa 26.7 20 33.4

Boost pressure mmHg 200 150 250

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 8.7

Boost pressure kPa 40 37.3 42.7

Boost pressure mmHg 300 280 320

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator operation limit position: L1 (3)Set idle sub-spring (4)Main spring setting
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K=15 L1=(10.5)mm
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Speed control lever angle

F:Full speed I:Idle D:Dead point (1)Stopper bolt setting
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a=18deg+-1deg b=29deg+-5deg c=20deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=12deg+-5deg b=46deg+-5deg

0000001501 LEVER

1. Variable lever adjustment (1)Fix lever (B) in the beginning of speed increase position using bolts (C) and (D). (2)Fix using the bolt E so that the lever A is aa. (3)Lock using bolt (G). (4)After completing idle adjustment, loosen the full side stopper bolt (D). (5)Move the lever (A) in the full speed direction. (6)Fix bolt (D) at full speed position. (7)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
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