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


101605-0190 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101605-0190
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

Test data 101605-0190
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101605-0190
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

Test data 101605-0190
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

Test data 101605-0190
(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)




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