101602-4940 ZEXEL 9 400 614 860 BOSCH INJECTION-PUMP ASSEMBLY 9400614860 1016024940 1156022320

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 860 9400614860

ZEXEL 101602-4940 1016024940

ISUZU 1156022320 1156022320

Service parts 101602-4940 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2180

3. GOVERNOR 105411-1220

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 105100-5053

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:

101602-4940 as INJECTION-PUMP ASSEMBLY

Include in #2:

104948-1010 as _

Cross reference number

BOSCH 9 400 614 860 9400614860

ZEXEL 101602-4940 1016024940

ISUZU 1156022320 1156022320

Zexel num

Bosch num

Firm num

Name

101602-4940

9 400 614 860

1156022320 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T 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 157 123 191

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 8.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 74.3 72.3 76.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point B

Rack position 8.1

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 77 75.5 78.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_03

Adjusting point C

Rack position 7.9

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 51.2 49.2 53.2

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. 12.1 10.8 13.4

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 8.8+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 49.2 49.2

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 7.9

Boost pressure kPa 7.3 2 12.6

Boost pressure mmHg 55 15 95

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 8.6

Boost pressure kPa 25.3 24 26.6

Boost pressure mmHg 190 180 200

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
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K=17
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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. (1)Normal
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a=2.5deg+-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)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(10deg)