101603-4881 ZEXEL 9 400 615 102 BOSCH INJECTION-PUMP ASSEMBLY 9400615102 1016034881 1156022603


101603-4881 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 102 9400615102
ZEXEL 101603-4881 1016034881
ISUZU 1156022603 1156022603

Service parts 101603-4881 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4600
3. GOVERNOR 105931-5090
4. SUPPLY PUMP 105210-5100
5. AUTOM. ADVANCE MECHANIS 105643-0650
6. COUPLING PLATE 105662-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6301
11. Nozzle and Holder 1-15300-263-1
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105030-4351
14. NOZZLE 105015-8640
15. NOZZLE SET

Include in #1:

101603-4881 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 102 9400615102
ZEXEL 101603-4881 1016034881
ISUZU 1156022603 1156022603


Zexel num
Bosch num
Firm num
Name
101603-4881 
9 400 615 102 
1156022603  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-S * K 14BF INJECTION PUMP ASSY 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 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   11.6
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   74.8 73.2 76.4
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   275 275 275
Average injection quantity mm3/st.   8 6.7 9.3
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(11.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   74.8 73.8 75.8
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.35
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   87.3 83.3 91.3
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   93 93 101
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1275--
Advance angle deg.   0 0 0
Load   3/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1225
Advance angle deg.   0.5
Load   3/4
Timer adjustment_03
Pump speed r/min   1275
Advance angle deg.   0.5
Load   4/4
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5.5 5 6
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4881
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C90
----------

Speed control lever angle

Test data 101603-4881
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=45mm
----------
a=21.5deg+-5deg b=38deg+-3deg

Stop lever angle

Test data 101603-4881
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101603-4881
(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=12deg
----------
a=(60deg)




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Group cross 101603-4881 ZEXEL

Isuzu 

 
1156023280 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023281 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023282 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022151 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022152 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022153 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 097 
1156022154 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023710 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156023711 
INJECTION-PUMP ASSEMBLY
6SA1
9 400 615 098 
1156023712 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156022741 
INJECTION-PUMP ASSEMBLY
6BD1T
9 400 615 099 
1156022742 
INJECTION-PUMP ASSEMBLY
6BD1-T
 
1156023032 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023033 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023034 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023035 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023036 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023037 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 100 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 100 
1156023038 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023720 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023721 
INJECTION-PUMP ASSEMBLY
6BG1TC
9 400 615 101 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 101 
1156023722 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156024300 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024301 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024310 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022602 
INJECTION-PUMP ASSEMBLY
6BG1S
101603-4881  
9 400 615 102 
1156022603 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156024320 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156024321 
INJECTION-PUMP ASSEMBLY
6BG1S
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