101606-0242 ZEXEL 9 400 612 657 BOSCH INJECTION-PUMP ASSEMBLY 9400612657 1016060242 1156034122

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 657 9400612657

ZEXEL 101606-0242 1016060242

ISUZU 1156034122 1156034122

Service parts 101606-0242 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6760

3. GOVERNOR 105411-2420

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:

101606-0242 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1690 as _

Cross reference number

BOSCH 9 400 612 657 9400612657

ZEXEL 101606-0242 1016060242

ISUZU 1156034122 1156034122

Zexel num

Bosch num

Firm num

Name

101606-0242

9 400 612 657

1156034122 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1MTCX K 14BF INJECTION PUMP ASSY 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 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 9.7

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 137.5 135.9 139.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 107 107

Boost pressure mmHg 800 800

Injection quantity adjustment_02

Adjusting point B

Rack position 4.3+-0.5

Pump speed r/min 275 275 275

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

Injection quantity adjustment_03

Adjusting point D

Rack position (12.8)+- 0.1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 195 195 205

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Boost compensatory excess lever at excess.

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 8.1

Boost pressure kPa 36.7 36.7 36.7

Boost pressure mmHg 275 275 275

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 8.7

Boost pressure kPa 53.3 50.6 56

Boost pressure mmHg 400 380 420

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position (9.7)

Boost pressure kPa 93.3 93.3 93.3

Boost pressure mmHg 700 700 700

Timer adjustment

Pump speed r/min 0

Advance angle deg. 0 0 0

Load 0/4

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min 500

Advance angle deg. 0 -0.5 0

Load 0/4

Timer adjustment_04

Pump speed r/min 700+-25

Advance angle deg. -2 -2.5 -1.5

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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Main spring setting
----------
K=11 L1=(12.8)+-0.1mm BCL=(1.6)+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=(22deg)+-5deg b=(32deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)Normal (3)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 (2)Rack position = aa at boost pressure 0.
----------
aa=(12.8)+-0.1mm
----------
a=(15deg) b=(25deg)+-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=15deg
----------
a=(60deg)