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


101606-0581 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101606-0581
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

Test data 101606-0581
F:Full speed I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 101606-0581
N:Pump normal S:Stop the pump. (1)Normal
----------

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

0000001501 TAMPER PROOF

Test data 101606-0581
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)
----------

Timing setting

Test data 101606-0581
(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)




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