101602-0871 ZEXEL 9 400 619 595 BOSCH INJECTION-PUMP ASSEMBLY 9400619595 1016020871 1156011524

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 595 9400619595

ZEXEL 101602-0871 1016020871

ISUZU 1156011524 1156011524

Service parts 101602-0871 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8390

3. GOVERNOR 105410-3800

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156612-7921

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

11. Nozzle and Holder 5-15300-103-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3391

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101602-0871 as INJECTION-PUMP ASSEMBLY

Include in #2:

104762-4091 as _

Cross reference number

BOSCH 9 400 619 595 9400619595

ZEXEL 101602-0871 1016020871

ISUZU 1156011524 1156011524

Zexel num

Bosch num

Firm num

Name

101602-0871
101602-8310

9 400 619 595

1156011524 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * K

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 2.4 2.35 2.45

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 10.3

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 59 57.2 60.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 56.6 55.1 58.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 4.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

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 CAP: R1 (4)Set idle sub-spring
----------
K=13 R1=(17.5)mm
----------

Speed control lever angle

I:Idle (1)Set the pump speed at aa (2)Stopper bolt setting (3)Set speed at bb (setting at shipping).
----------
aa=750r/min bb=900r/min
----------
a=1deg+-5deg b=4.5deg+-5deg c=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=4.5deg+-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=20deg
----------
a=(90deg)