101603-4460 ZEXEL 9 400 619 551 BOSCH INJECTION-PUMP ASSEMBLY 9400619551 1016034460 1156022212

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 619 551 9400619551

ZEXEL 101603-4460 1016034460

ISUZU 1156022212 1156022212

Service parts 101603-4460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0570

3. GOVERNOR 105931-4361

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS 105612-3220

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

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

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101492-0242 as _

101603-4460 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 551 9400619551

ZEXEL 101603-4460 1016034460

ISUZU 1156022212 1156022212

Zexel num

Bosch num

Firm num

Name

101603-4460
101603-4461

9 400 619 551

1156022212 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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 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 3.6 3.55 3.65

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 10.9

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.3 58.7 61.9

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 H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8.7 7.4 10

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.9)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 60.3 59.3 61.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point C

Rack position R1-0.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 64 62.4 65.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position R1(10.9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 46.9 45.3 48.5

Fixing the lever *

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. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 3.2 2.7 3.7

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)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=19 RAL=13.6+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=39deg+-5deg b=36deg+-3deg

Stop lever angle

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

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

0000001501 TAMPER PROOF

Tamper proof adjustment (1)Set the full load screw at rack position Ra+0.4. (2)Set the full load position Ra using screw (A).
----------
Ra=R1(10.9)+0.4mm
----------

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)