101602-4680 ZEXEL 9 400 612 456 BOSCH INJECTION-PUMP ASSEMBLY 9400612456 1016024680 1156018220

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 456 9400612456

ZEXEL 101602-4680 1016024680

ISUZU 1156018220 1156018220

Service parts 101602-4680 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2860

3. GOVERNOR 105410-8520

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5053

11. Nozzle and Holder 1-15300-105-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101602-4680 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-1460 as _

Cross reference number

BOSCH 9 400 612 456 9400612456

ZEXEL 101602-4680 1016024680

ISUZU 1156018220 1156018220

Zexel num

Bosch num

Firm num

Name

101602-4680

9 400 612 456

1156018220 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1T 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 opening pressure kPa 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 8.5

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 85.4 83.9 86.9

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.2+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 12.1 10.8 13.4

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)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Rack difference between N = N1 and N = N2
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K=11 N1=1250r/min N2=650r/min
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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=20deg+-3deg c=(26deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
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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 the bolts C and D. (2)Temporarily fix lever A in center of long hole. (3)Set the dead point position temporarily and measure the lever angle. (4)After idle adjustment, loosen the full side stopper bolt D. (5)Move lever A in full speed direction. (6)Fix the bolt D at the full speed position. (7)Fix lever A using bolt E. (8)(G) Lock using bolt. (9)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)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
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aa=17deg
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a=(10deg)