101606-0240 ZEXEL 9 400 612 263 BOSCH INJECTION-PUMP ASSEMBLY 9400612263 1016060240 1156034120

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 263 9400612263

ZEXEL 101606-0240 1016060240

ISUZU 1156034120 1156034120

Service parts 101606-0240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6760

3. GOVERNOR 105411-1670

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105672-0810

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7463

11. Nozzle and Holder 1-15300-307-3

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}

13. NOZZLE-HOLDER 105030-3231

14. NOZZLE 105015-9140

15. NOZZLE SET

Include in #1:

101606-0240 as INJECTION-PUMP ASSEMBLY

Include in #2:

104701-1003 as _

Cross reference number

BOSCH 9 400 612 263 9400612263

ZEXEL 101606-0240 1016060240

ISUZU 1156034120 1156034120

Zexel num

Bosch num

Firm num

Name

101606-0240
101606-0241

9 400 612 263

1156034120 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1MTCX * 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 10.3

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 144.5 142.9 146.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 127 127

Boost pressure mmHg 950 950

Injection quantity adjustment_02

Adjusting point B

Rack position 4.4+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 13.5 12.2 14.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 8

Boost pressure kPa 40 37.3 42.7

Boost pressure mmHg 300 280 320

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position (10.3)

Boost pressure kPa 113 113 113

Boost pressure mmHg 850 850 850

Timer adjustment

Pump speed r/min 0

Advance angle deg. 2 1.5 2.5

Load 0/4

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 2 1.5 2.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min 700+-25

Advance angle deg. 0 0 0

Load 0/4

Remarks
Finish

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)Supply with excess fuel lever not operating. (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=14 BCL=(2.3)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=(28deg)+-5deg b=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=40mm
----------
a=32deg+-5deg b=(55deg)

0000001101

N:Normal B:When boosted (1)Drive side
----------

----------
a=(15deg) b=(30deg)+-5deg

Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)