101605-0190 ZEXEL 9 400 615 320 BOSCH INJECTION-PUMP ASSEMBLY 9400615320 1016050190 1156034510

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 320 9400615320

ZEXEL 101605-0190 1016050190

ISUZU 1156034510 1156034510

Service parts 101605-0190 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8920

3. GOVERNOR 105411-2401

4. SUPPLY PUMP

105220-7250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-9120

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4170

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101605-0190 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1032 as _

Cross reference number

BOSCH 9 400 615 320 9400615320

ZEXEL 101605-0190 1016050190

ISUZU 1156034510 1156034510

Zexel num

Bosch num

Firm num

Name

101605-0190

9 400 615 320

1156034510 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T K

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 9

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 102.5 101 104

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_02

Adjusting point C

Rack position 5.9+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 9.2++

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 R1-0.35

Boost pressure kPa 34.7 30.7 38.7

Boost pressure mmHg 260 230 290

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(9)

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

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 (6)Boost compensator stroke: BCL
----------
K=8 BCL=0.35+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=8deg+-5deg b=26deg+-5deg

Stop lever angle

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=32deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (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

(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)