101605-0340 ZEXEL 9 400 613 437 BOSCH INJECTION-PUMP ASSEMBLY 9400613437 1016050340 1156035040

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 437 9400613437

ZEXEL 101605-0340 1016050340

ISUZU 1156035040 1156035040

Service parts 101605-0340 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8550

3. GOVERNOR 105411-2680

4. SUPPLY PUMP

105220-7230

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 1-15300-432-1

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}

13. NOZZLE-HOLDER 105041-4410

14. NOZZLE

15. NOZZLE SET 105019-2900

Include in #1:

101491-0750 as _

101605-0340 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 437 9400613437

ZEXEL 101605-0340 1016050340

ISUZU 1156035040 1156035040

Zexel num

Bosch num

Firm num

Name

101605-0340
101605-0341

9 400 613 437

1156035040 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T * K 14BF 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 10.3

Pump speed r/min 975 975 975

Average injection quantity mm3/st. 89.5 88 91

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 74.6 74.6

Boost pressure mmHg 560 560

Injection quantity adjustment_02

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 15 13.7 16.3

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 10.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 65 75

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 R1-0.7

Boost pressure kPa 37.3 33.3 41.3

Boost pressure mmHg 280 250 310

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.3)

Boost pressure kPa 61.3 54.6 68

Boost pressure mmHg 460 410 510

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=9 BCL=0.7+-0.1mm
----------

Speed control lever angle

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

----------
a=2deg+-5deg b=16deg+-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=8deg
----------
a=(100deg)