101602-4402 ZEXEL 9 400 614 838 BOSCH INJECTION-PUMP ASSEMBLY 9400614838 1016024402 1156018212

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 838 9400614838

ZEXEL 101602-4402 1016024402

ISUZU 1156018212 1156018212

Service parts 101602-4402 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4080

3. GOVERNOR 105410-8022

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101602-4402 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-0030 as _

Cross reference number

BOSCH 9 400 614 838 9400614838

ZEXEL 101602-4402 1016024402

ISUZU 1156018212 1156018212

Zexel num

Bosch num

Firm num

Name

101602-4402
101602-7050

9 400 614 838

1156018212 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * 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 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 3.6 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 9.1

Pump speed r/min 1100 1100 1100

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 B

Rack position 7.2+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8.4 7 9.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting (4)Rack difference between N = N1 and N = N2
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K=13 N1=1100r/min N2=800r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=18deg+-1deg b=22deg+-5deg

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 idle position using bolts (C) and (D). (2)Temporarily fix the lever (A) at the dead point and measure the lever angle . (3)Fix the lever (A) at the idle lever angle position using the bolt (E). (4)Lock using bolt (G). (5)After completing idle adjustment, loosen the full side stopper bolt (D). (6)Move the lever (A) in the full speed direction. (7)Fix bolt (D) at full speed position. (8)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
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Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)- (4)-
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a=(10deg)