101602-8370 ZEXEL 9 400 610 624 BOSCH INJECTION-PUMP ASSEMBLY 9400610624 1016028370 1156032200

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 624 9400610624

ZEXEL 101602-8370 1016028370

ISUZU 1156032200 1156032200

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Buy INJECTION-PUMP ASSEMBLY 101602-8370 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-8370 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6440

3. GOVERNOR 105411-1850

4. SUPPLY PUMP 105220-6240

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156639-0320

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:

101492-0370 as _

101602-8370 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 624 9400610624

ZEXEL 101602-8370 1016028370

ISUZU 1156032200 1156032200

Zexel num

Bosch num

Firm num

Name

101602-8370

9 400 610 624

1156032200 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 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 9.2

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 106.5 105 108

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_02

Adjusting point C

Rack position 5.9+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 10 8.7 11.3

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_03

Adjusting point D

Rack position R1-1.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 50.5 46.5 54.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1.2

Boost pressure kPa 4 4 8

Boost pressure mmHg 30 30 60

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(9.2)

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=9 BCL=1.2+-0.1mm
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (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)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

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=(20deg)

Information:

Operations that may cause product damage are identified by notice labels in this publication.
Introduction
This Tool Operating Manual contains two filter installation procedures. This first procedure is for installing a primary filter system. This is a coarse filter and will protect the transfer pump from contamination in the oil. The second procedure outlines installing a secondary filter which is designed to protect injection pumps from contaminated oil. Fuel injection pumps used on the 3208 Engine are one example of a fuel injection pump that requires the secondary filter installation.It will be the dealer choice as to which optional filter is installed on the test stand. Determine what type of filtering will be required most often, and install the appropriate type of filtering system. These filters can only be added to the 15 horsepower test stands.Secondary Filter
Nomenclature
Illustration 1. Nomenclature for Secondary Filter Installation. Refer to Chart A for item identification. Fabricated Parts
All the parts required for this installation can be ordered from Caterpillar Parts Distribution, except bracket (1). This must be manufactured by the bench owner, using the dimensions provided below.This bracket can be made from common SAE1018 steel. Weld the two pieces together.
Illustration 2. Filter Mounting Bracket. Refer to Chart B for dimensions. Installation
Assemble the Fuel Filter
1. Install 053-0088 Fitting (17) with 3J-1907 Seal (18) into the inlet port (left side) of the filter base. (This converts a number 6 STOP port to NPT). Install 5P-4455 Fitting (19) into fitting (17).2. Install 2R-6806 Fitting (15) with 3J-1907 Seal (16) into the outlet port (right side) of the filter base.3. Install 6N-4414 Cover (7) onto the filter base using 1P-0436 Gasket (8), 4B-3388/6V-2317 (9), and OS-1616/6V-8490 Bolt (10).4. Install 9S-4182 Plug (5) with 6V-5084 O-ring Seal (6) into the top of the filter base.5. Install the filter base assembly onto filter bracket (1),