101603-4130 ZEXEL 9 400 615 073 BOSCH INJECTION-PUMP ASSEMBLY 9400615073 1016034130 1156021230

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 073 9400615073

ZEXEL 101603-4130 1016034130

ISUZU 1156021230 1156021230

Service parts 101603-4130 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2791

3. GOVERNOR 105410-7300

4. SUPPLY PUMP 105210-6530

5. AUTOM. ADVANCE MECHANIS 105644-0021

6. COUPLING PLATE 105662-0630

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5442

11. Nozzle and Holder 1-15300-103-2

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

13. NOZZLE-HOLDER 105031-3782

14. NOZZLE 105015-4390

15. NOZZLE SET

Include in #1:

101492-0201 as _

101603-4130 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 073 9400615073

ZEXEL 101603-4130 1016034130

ISUZU 1156021230 1156021230

Zexel num

Bosch num

Firm num

Name

101603-4130

9 400 615 073

1156021230 ISUZU

INJECTION-PUMP ASSEMBLY
6QA1 * 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 131424-0220

Overflow valve opening pressure kPa 147 113 181

Overflow valve opening pressure kgf/cm2 1.5 1.15 1.85

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 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 75.4 74.4 76.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.6

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 130.8 128.8 132.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 7.7 12.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.8 0.1 0.8

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 0.8 0.3 1.3

Timer adjustment_04

Pump speed r/min 900

Advance angle deg. 2 1.5 2.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 4 4 4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1.
----------
K=6 L1=9.2+0.5mm
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=5deg+-5deg c=23deg+-5deg d=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=10deg+-5deg b=53deg+-5deg

0000001501 LEVER

1. Variable lever adjustment (1)Set lever (a) in the idle position. (2)Set lever (c) at the dead point using screw (b) and then fix using bolt (d). (3)When the dead point position cannot be obtained, set the lever (c) at the position closest to the dead point (at the end of the elongated hole) (in the direction of arrow A).
----------

----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=17deg
----------
a=(60deg)