101603-4402 ZEXEL 9 400 610 649 BOSCH INJECTION-PUMP ASSEMBLY 9400610649 1016034402 1156022364

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 649 9400610649

ZEXEL 101603-4402 1016034402

ISUZU 1156022364 1156022364

Service parts 101603-4402 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4830

3. GOVERNOR 105932-2120

4. SUPPLY PUMP 105220-5910

5. AUTOM. ADVANCE MECHANIS 105612-3140

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5053

11. Nozzle and Holder 1-15300-105-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101492-0221 as _

101603-4402 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 649 9400610649

ZEXEL 101603-4402 1016034402

ISUZU 1156022364 1156022364

Zexel num

Bosch num

Firm num

Name

101603-4402

9 400 610 649

1156022364 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1-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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.4 3.35 3.45

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 -

Rack position 10.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67 65.4 68.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67 66 68

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 74.5 71.3 77.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.4)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 68.5 64.5 72.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 42.7 39.5 45.9

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position (R1-0.2)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 42.8 39.6 46

Fixing the lever *

Injection quantity adjustment_08

Adjusting point F

Rack position (R1+0.15 )

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 42.4 39.2 45.6

Fixing the lever *

Injection quantity adjustment_09

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 81 81 91

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E66
----------

Speed control lever angle

F:Full speed I:Idle (1)- (2)Stopper bolt set position 'H'
----------

----------
a=33deg+-5deg b=36deg+-3deg

Stop lever angle

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

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=900 r/min L1=(1.5) mm L2=11+-0.5 mm h1=0.15
----------
Ra=R1(10.6) mm Rb=R2(10.1) mm Pa=89.8+-2.7 kPa(674+-20 mmHg) Pb=70.1+-0.7 kPa(526+-5 mmHg) Q1=67+-1 cm3/1000st Q2=56.5+-1.6 cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(60deg)