101605-0100 ZEXEL 9 400 612 260 BOSCH INJECTION-PUMP ASSEMBLY 9400612260 1016050100 1156033960


101605-0100 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 612 260 9400612260
ZEXEL 101605-0100 1016050100
ISUZU 1156033960 1156033960

Service parts 101605-0100 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8410
3. GOVERNOR 105411-2300
4. SUPPLY PUMP 105220-6640
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156643-4820
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5241
11. Nozzle and Holder 1-15300-421-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-4750
14. NOZZLE 105025-3730
15. NOZZLE SET

Include in #1:

101605-0100 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 612 260 9400612260
ZEXEL 101605-0100 1016050100
ISUZU 1156033960 1156033960


Zexel num
Bosch num
Firm num
Name
101605-0100 
9 400 612 260 
1156033960  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   134424-4120
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   4.2 4.15 4.25
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   11
Pump speed r/min   1075 1075 1075
Average injection quantity mm3/st.   110.5 109 112
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   105 105
Boost pressure mmHg   790 790
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.7+-0.5
Pump speed r/min   450 450 450
Average injection quantity mm3/st.   12 10.7 13.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   D
Rack position   11.2++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   105 100 110
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   R2-0.3
Boost pressure kPa   53.3 49.3 57.3
Boost pressure mmHg   400 370 430
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2(10)
Boost pressure kPa   92 85.3 98.7
Boost pressure mmHg   690 640 740

Test data Ex:

Governor adjustment

Test data 101605-0100
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)Boost compensator stroke: BCL (6)Main spring setting
----------
K=16 BCL=0.3+-0.1mm
----------

Speed control lever angle

Test data 101605-0100
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(3deg)+-5deg b=(20deg)+-5deg

Stop lever angle

Test data 101605-0100
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=50deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Test data 101605-0100
Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (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

Test data 101605-0100
(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=9deg
----------
a=(100deg)




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