101602-8440 ZEXEL 9 400 610 629 BOSCH INJECTION-PUMP ASSEMBLY 9400610629 1016028440 1156032230


101602-8440 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 629 9400610629
ZEXEL 101602-8440 1016028440
ISUZU 1156032230 1156032230

Service parts 101602-8440 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8830
3. GOVERNOR 105419-2640
4. SUPPLY PUMP 105220-6240
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
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:

101602-8440 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 629 9400610629
ZEXEL 101602-8440 1016028440
ISUZU 1156032230 1156032230


Zexel num
Bosch num
Firm num
Name
101602-8440 
101602-8441 
9 400 610 629 
1156032230  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TQA * K 14BF 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   10.3
Pump speed r/min   1075 1075 1075
Average injection quantity mm3/st.   89.5 88 91
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7.4+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   9.5 8.2 10.8
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   85 80 90
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 101602-8440
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
----------
K=12
----------

Speed control lever angle

Test data 101602-8440
F:Full speed I:Idle D:Dead point (1)Pump speed = aa
----------
aa=1095r/min
----------
a=20deg+-3deg b=18deg+-1deg c=(19deg)+-5deg d=(2deg)

Stop lever angle

Test data 101602-8440
N:Pump normal S:Stop the pump.
----------

----------
a=13deg+-5deg b=53deg+-5deg

0000001501 LEVER

Test data 101602-8440
1. Variable lever adjustment (1)Fix lever (B) in the idle position using bolts (C) and (D). (2)Temporarily fix the lever (A) in the center of the elongated hole. (3)Set the dead point position temporarily and measure the lever angle. (4)Fix the lever (A) at the idle lever angle position using the bolt (E). (5)Lock using bolt (G). (6)After completing idle adjustment, loosen the full side stopper bolt (D). (7)Move the lever (A) in the full speed direction. (8)Fix bolt (D) at full speed position. (9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------

----------

Timing setting

Test data 101602-8440
(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=12deg
----------
a=(100deg)




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