101602-8991 ZEXEL 9 400 611 829 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 611 829 9400611829
ZEXEL 101602-8991 1016028991
ISUZU 1156033781 1156033781

Service parts 101602-8991 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8390
3. GOVERNOR 105419-4140
4. SUPPLY PUMP 105220-6240
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156639-0320
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5130
11. Nozzle and Holder 8-97222-170-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-4750
14. NOZZLE 105025-3040
15. NOZZLE SET

Include in #1:

101602-8991 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 611 829 9400611829
ZEXEL 101602-8991 1016028991
ISUZU 1156033781 1156033781


Zexel num Bosch num Firm num Firm Name
101602-8991 
101602-8992 
9 400 611 829  1156033781  ISUZU INJECTION-PUMP ASSEMBLY
6BG1-T * K 14BF PE6AD PE

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-5-3-6- 2-4
Pre-stroke mm   4 3.95 4.05
Beginning of injection position   NO.1
Drive side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


Injection quantity adjustment
Adjusting point   A
Rack position   10.2
Pump speed r/min   1075 1075 1075
Average injection quantity mm3/st.   86 84.5 87.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *


Injection quantity adjustment_02
Adjusting point   C
Rack position   7.5+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   9 7.7 10.3
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.   150 145 155
Fixing the lever   *
Rack limit   *

Test data Ex:



Governor adjustment

Test data 101602-8991 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)Set at delivery
----------
K=9
----------



Speed control lever angle

Test data 101602-8991 F:Full speed I:Idle S:Stop D:Dead point (1)When pump speed set at aa (2)Set the pump speed at bb (at delivery) (3)Stopper bolt setting
----------
aa=1075r/min bb=1125r/min
----------
a=(20deg)+-3deg b=16.5deg+-5deg c=(3deg) d=20deg+-5deg e=18.5deg+-5deg



Stop lever angle

Test data 101602-8991 N:Pump normal S:Stop the pump. (1)Normal
----------

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



0000001501 LEVER

Test data 101602-8991 1. Variable lever adjustment (1)Fix lever B in the idle position using the bolts C and D. (2)Temporarily fix lever A in center of long hole. (3)Set the dead point position temporarily and measure the lever angle. (4)After idle adjustment, loosen the full side stopper bolt D. (5)Move lever A in full speed direction. (6)Fix the bolt D at the full speed position. (7)Fix lever A using bolt E. (8)(G) Lock using bolt. (9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------

----------



Timing setting

Test data 101602-8991 (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=10deg
----------
a=(100deg)





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Group cross 101602-8991 ZEXEL

Isuzu 

101602-8900 
101602-8901 
9 400 611 696  1156033490  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8901 
101602-8902 
F 01G 09U 0HV    INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8902      INJECTION-PUMP ASSEMBLY

Isuzu 

101602-8903 
101605-0300 
9 400 612 656  1156033491  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8910  9 400 612 070  1156033270  INJECTION-PUMP ASSEMBLY
6BG1
101602-8920  9 400 614 964  1156033560  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8930  9 400 611 942  1156033550  INJECTION-PUMP ASSEMBLY
6BG1
101602-8940  9 400 614 965  1156033510  INJECTION-PUMP ASSEMBLY
6BG1
101602-8950 
101602-8990 
9 400 611 253  1156033280  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8960  9 400 614 966  1156033620  INJECTION-PUMP ASSEMBLY
6BG1
101602-8970  9 400 614 967  1156033690  INJECTION-PUMP ASSEMBLY
6BG1-TQJ
101602-8980 
101602-8981 
9 400 611 895  1156033710  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8981  9 400 612 258  1156033711  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8990 
101602-8991 
F 01G 09U 03D  1156033780  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8991 
101602-8992 
9 400 611 829  1156033781  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8992 
101602-8993 
9 400 612 530  1156033782  INJECTION-PUMP ASSEMBLY
6BG1-T
101602-8993  9 400 619 532  1156033783  INJECTION-PUMP ASSEMBLY
6BG1-T
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