101606-0581 ZEXEL 9 400 613 470 BOSCH INJECTION-PUMP ASSEMBLY 9400613470 1016060581 1156035011

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 470 9400613470

ZEXEL 101606-0581 1016060581

ISUZU 1156035011 1156035011

Service parts 101606-0581 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6851

3. GOVERNOR 105411-2720

4. SUPPLY PUMP

105220-7230

5. AUTOM. ADVANCE MECHANIS 105672-0840

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

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:

101606-0581 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6212 as _

Cross reference number

BOSCH 9 400 613 470 9400613470

ZEXEL 101606-0581 1016060581

ISUZU 1156035011 1156035011

Zexel num

Bosch num

Firm num

Name

101606-0581
101606-0582

9 400 613 470

1156035011 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 1100 1100 1100

Average injection quantity mm3/st. 95 93.5 96.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 124 124

Boost pressure mmHg 930 930

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 425 425 425

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.

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R1-1.05

Boost pressure kPa 48 48 48

Boost pressure mmHg 360 360 360

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R1-0.7

Boost pressure kPa 68 62 74

Boost pressure mmHg 510 465 555

Boost compensator adjustment_03

Pump speed r/min 550 550 550

Rack position R1(10.3)

Boost pressure kPa 111 111 111

Boost pressure mmHg 830 830 830

Timer adjustment

Pump speed r/min 1300++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1300.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

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)Set idle sub-spring (4)Boost compensator stroke: BCL (5)Main spring setting
----------
K=10 BCL=1.05+-0.1mm
----------

Speed control lever angle

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

----------
a=7deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=53deg+-5deg b=45deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (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) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
----------
T1=2.5N-m(0.25kgf-m) T2=2.94~4.41N-m(0.3~0.45kgf-m) T3=29.4~39.2N-m(3~4kgf-m)
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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=6deg
----------
a=(90deg)