101605-0200 ZEXEL 9 400 612 998 BOSCH INJECTION-PUMP ASSEMBLY 9400612998 1016050200 1156034530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 998 9400612998

ZEXEL 101605-0200 1016050200

ISUZU 1156034530 1156034530

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Buy INJECTION-PUMP ASSEMBLY 101605-0200 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-0200 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8550

3. GOVERNOR 105411-2540

4. SUPPLY PUMP

105220-7230

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156643-2020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5120

11. Nozzle and Holder 1-15300-394-0

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

13. NOZZLE-HOLDER 105030-4750

14. NOZZLE 105025-3030

15. NOZZLE SET

Include in #1:

101605-0200 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1040 as _

Cross reference number

BOSCH 9 400 612 998 9400612998

ZEXEL 101605-0200 1016050200

ISUZU 1156034530 1156034530

Zexel num

Bosch num

Firm num

Name

101605-0200

9 400 612 998

1156034530 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T K 14BE INJECTION PUMP ASSY PE6A 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 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 9.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 82 80.5 83.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 70.6 70.6

Boost pressure mmHg 530 530

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 450 450 450

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.

Injection quantity adjustment_03

Adjusting point E

Rack position 10.1++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 110 120

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 R1-0.6

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(9.9)

Boost pressure kPa 57.3 50.6 64

Boost pressure mmHg 430 380 480

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Boost compensator stroke: BCL (5)Main spring setting
----------
K=10 BCL=0.6+-0.1mm
----------

Speed control lever angle

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

----------
a=(0deg)+-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=7.5deg
----------
a=(100deg)

Information:

(1) Governor front housing.(2) Joint face between front housing and rear housing.(3) Governor rear housing.(4) Dashpot spring (7C4466). Color code ... one dark green stripeRate test:a. Put a load on spring of ... 20 N (4.5 lb)b. Compress spring an additional ... 5 mm (.197 in)c. Total test force ... 50.0 1.5 N (11.25 .34 lb)d. Free length after test ... 39.5 mm (1.555 in)(5) Tighten 8 bolts to a torque of ... 10 1 N m (90 9 lb in)(6) Shims. Install shims as required to provide dimension (A) between joint face (2) of governor housing and riser groove. Refer to Disassembly and Assembly Section of this Service Manual, for the correct tools and procedure to check dimension (A).Dimension (A) ... 20.00 0.08 mm (.787 .003 in)(7) Riser.(8) Riser lever swivel.(9) Spring group (9Y4027) Inner spring (9Y2589) ... Low idle springColor code ... one violet stripe, one dark blue stripeRate test:a. Put a load on spring of ... 60 N (13.5 lb)b. Compress spring an additional ... 10 mm (.394 in)c. Total test force ... 130.0 2.6 N (29.25 .6 lb)d. Free length after test ... 47.02 0.50 mm (1.851 .02 in)Outer spring (9Y4028) ... High idle springColor code ... one red stripe, one light blue stripeRate test:a. Put a load on spring of ... 100 N (22.5 lb)b. Compress spring an additional ... 10 mm (.394 in)c. Total test force ... 252.0 4.8 N (56.7 1.1 lb)d. Free length after test ... 62.31 0.50 mm (2.453 .02 in)(10) Shims. Install shims as required to provide the correct governor spring preload dimension. Refer to the Diassembly and Assembly Section of this Service Manual, for the correct tools and procedure to check the governor spring preload dimension.
View Into Rear Housing(11) Torque lever.
View A-A(12) Throttle spring (7W9526) (part of governor front housing assembly). Type ... torsionalRate per 360° ... 1.054 N m (9.38 lb in)Preload in assembled position ... 270°(13) Torque cam.
View B-B(8) Riser lever swivel.(11) Torque lever.(13) Torque cam.(15) Torque cam setscrew. Refer to the Disassembly And Assembly Section of this Service Manual, for the complete procedure for setting torque cam. The 1U7310 Torque Cam Adjustment Tool (part of 1U7315 Governor Disassembly And Assembly Tool Group) is required to check/adjust the torque cam.