101602-0970 ZEXEL 9 400 614 709 BOSCH INJECTION-PUMP ASSEMBLY 9400614709 1016020970 1156008814

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 709 9400614709

ZEXEL 101602-0970 1016020970

ISUZU 1156008814 1156008814

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Buy INJECTION-PUMP ASSEMBLY 101602-0970 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-0970 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8130

3. GOVERNOR 105410-5100

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-3921

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

11. Nozzle and Holder 5-15300-103-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3391

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101602-0970 as INJECTION-PUMP ASSEMBLY

101609-3260 as _

101609-3261

Cross reference number

BOSCH 9 400 614 709 9400614709

ZEXEL 101602-0970 1016020970

ISUZU 1156008814 1156008814

Zexel num

Bosch num

Firm num

Name

101602-0970

9 400 614 709

1156008814 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * 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 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 8.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 55.4 54.4 56.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.7+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

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
----------
K=13
----------

Speed control lever angle

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

----------
a=4deg+-5deg b=28deg+-3deg

Stop lever angle

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

----------
a=12deg+-5deg b=46deg+-5deg

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=20deg
----------
a=(90deg)

Information:

The DATA SET screen ID (2) for the correct group will be listed to the right of Line 011 FUEL INJECT PUMP BENCH TEST SPEC NUM (3). Write this number DMXXXX-XX down and proceed to Section ""Displaying the DATA SET Screen When the DATA SET ID Number is Not Known"".Certain pump and governor groups will have multiple DATA SETS. Change in pump design will be tracked by pump serial number. Figure 22 is an example of a serial l number break in the data (1). The original DATA SET DMXXXX number is kept (2) but the new DATA SET has a different change level (3).
Illustration 22 g02797952
Note: Soon you will be able to use the tab key to place the cursor in front of this line. Type an X to select, Figure 21 (4). Press the enter key. The data will be displayed automatically. For now though the data will have to be displayed manually. Figure 23 (1)
Illustration 23 g02797956
Press the pf3 key to return to the ACF2 screen (2) .Proceed to Section ""Displaying the DATA SET Screen When the DATA SET ID Number is Not Known"".Displaying the DATA SET Screen When the DATA SET ID Number is Not Known
At the ACF2/IMS ONLINE MENU SYSTEM screen (1) (TMI 1.04) press the enter key (2). Figure 24
Illustration 24 g02797958
This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 25 (1) (TMI 1.05)
Illustration 25 g02797959
Use the tab key to place the cursor in front of the line GKN402 TMI - ENGINE AND COMP PERF, type an X to select (2) or type GKN402 at the APPLICATION SELECTION NO. _. (3) Press the enter key. This will display the ACF2/IMS PROGRAM SELECTION MENU screen. Figure 26 (1)
Illustration 26 g02797960
Use the tab key to place the cursor in front of line 03 and type an X to select (2) or type 03 at the PROGRAM SELECTION NO _ (3). Press the enter key. This will display the PERFORMANCE PARAMETERS INQUIRY screen. Figure 27 (1) (TMI 3.03 p1)
Illustration 27 g02797962
Type the appropriate numbers in the DATA REFERENCE NUMBER and CHANGE LEVEL fields (2). Press the enter key. The data set will be displayed on the next screen. Figure 28 (TMI 3.03)
Illustration 28 g02797963
Press the pf3 key to return to the ACF2 screen (1) .Interpreting the Specification Data Set Screens
The following screen contains flow specifications and physical parameters necessary to evaluate a fuel injection pump. Additional parameters such as calibration fluid temperatures and pressures are listed in the manual for the test bench. See Special Instruction, SEHS8200. These screens still apply to this data. Every data set (DMXXXX screen) contains data for many injection pump and governor group part numbers. The data is sorted by the profile or geometry of the basic cam and the lowest level part number of the plunger and barrel group. Most part numbers with the same basic cam, plunger, and barrel groups use the same data.Pages of data in the DATA SETS are arranged in descending pump rpm. Five or six rpm choices are listed. When the