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


101602-8881 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101602-8881
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

Test data 101602-8881
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101602-8881
N:Pump normal S:Stop the pump. (1)Normal
----------

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

0000001501 TAMPER PROOF

Test data 101602-8881
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)
----------

Timing setting

Test data 101602-8881
(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)




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