101602-8881 ZEXEL 9 400 612 784 BOSCH INJECTION-PUMP ASSEMBLY 9400612784 1016028881 1156033471

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 784 9400612784

ZEXEL 101602-8881 1016028881

ISUZU 1156033471 1156033471

Service parts 101602-8881 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6700

3. GOVERNOR 105411-2480

4. SUPPLY PUMP 105220-6240

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-1200

7. COUPLING PLATE 156643-1320

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4170

11. Nozzle and Holder 1-15300-331-0

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101602-8881 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6533 as _

Cross reference number

BOSCH 9 400 612 784 9400612784

ZEXEL 101602-8881 1016028881

ISUZU 1156033471 1156033471

Zexel num

Bosch num

Firm num

Name

101602-8881

9 400 612 784

1156033471 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T K 14BF INJECTION PUMP ASSY PE6AD 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 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 3.6 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 10.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 93.5 92 95

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point C

Rack position 7.3+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 11 9.7 12.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.55

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.7)

Boost pressure kPa 20 14.7 25.3

Boost pressure mmHg 150 110 190

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)Boost compensator stroke: BCL
----------
K=13 BCL=0.55+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(4deg)+-5deg b=(18deg)+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
----------
T1=2.5N-m(0.25kgf-m) T2=2.94~4.41N-m(0.3~0.45kgf-m) T3=29.4~39.2N-m(3~4kgf-m)
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Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(60deg)