101605-0270 ZEXEL 9 400 613 051 BOSCH INJECTION-PUMP ASSEMBLY 9400613051 1016050270 1156034800


101605-0270 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 051 9400613051
ZEXEL 101605-0270 1016050270
ISUZU 1156034800 1156034800

Service parts 101605-0270 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-8410
3. GOVERNOR 105411-2610
4. SUPPLY PUMP 105220-6640
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156643-1720
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-8341
11. Nozzle and Holder 1-15300-432-0
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}
13. NOZZLE-HOLDER 105041-4410
14. NOZZLE
15. NOZZLE SET 105019-2880

Include in #1:

101605-0270 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 051 9400613051
ZEXEL 101605-0270 1016050270
ISUZU 1156034800 1156034800


Zexel num
Bosch num
Firm num
Name
101605-0270 
9 400 613 051 
1156034800  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   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   10.9
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   111 109.5 112.5
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   113 113
Boost pressure mmHg   850 850
Injection quantity adjustment_02
Adjusting point   -
Rack position   7.8+-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   E
Rack position   11.1++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 90 100
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   R1-1.35
Boost pressure kPa   34 30 38
Boost pressure mmHg   255 225 285
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(10.9)
Boost pressure kPa   100 93.3 106.7
Boost pressure mmHg   750 700 800

Test data Ex:

Governor adjustment

Test data 101605-0270
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=18 BCL=1.35+-0.1mm
----------

Speed control lever angle

Test data 101605-0270
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=21deg+-5deg

Stop lever angle

Test data 101605-0270
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 101605-0270
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 101605-0270
(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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