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

Information Cross number Calibration Data Calibration Data Ex

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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:

101482-4291 as _

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

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
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K=12
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Speed control lever angle

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

Stop lever angle

N:Pump normal S:Stop the pump.
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a=13deg+-5deg b=53deg+-5deg

0000001501 LEVER

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.
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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)-
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aa=12deg
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a=(100deg)