101602-7960 ZEXEL 9 400 610 607 BOSCH INJECTION-PUMP ASSEMBLY 9400610607 1016027960 1156030660

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 607 9400610607

ZEXEL 101602-7960 1016027960

ISUZU 1156030660 1156030660

Service parts 101602-7960 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8060

3. GOVERNOR 105419-0300

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-5520

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:

101401-0890 as _

101602-7960 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 607 9400610607

ZEXEL 101602-7960 1016027960

ISUZU 1156030660 1156030660

Zexel num

Bosch num

Firm num

Name

101602-7960

9 400 610 607

1156030660 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1-T 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 172

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-4920

Overflow valve opening pressure kPa 127 127 127

Overflow valve opening pressure kgf/cm2 1.3 1.3 1.3

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 3.2 3.15 3.25

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

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 71 69.5 72.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

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
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K=7
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Speed control lever angle

I:Idle D:Dead point (1)Speed set at aa (setting at supply) (2)When pump speed set at bb
----------
aa=900r/min bb=750r/min
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a=13deg+-5deg b=18deg+-5deg c=18deg+-1deg d=(20deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=2.5deg+-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 gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=17deg
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a=(90deg)