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


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 Firm 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   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.6 3.55 3.65
Beginning of injection position   NO.1
Drive side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


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 

101603-4800 
101603-4802 
  1156023280  INJECTION-PUMP ASSEMBLY
6BG1
101603-4801 
101603-4802 
  1156023281  INJECTION-PUMP ASSEMBLY
6BG1
101603-4802    1156023282  INJECTION-PUMP ASSEMBLY
6BG1
101603-4810 
101603-4813 
  1156022151  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4811 
101603-4813 
  1156022152  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4812 
101603-4813 
  1156022153  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4813  9 400 615 097  1156022154  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4820 
101603-4822 
  1156023710  INJECTION-PUMP ASSEMBLY
6SA1
101603-4821 
101603-4822 
  1156023711  INJECTION-PUMP ASSEMBLY
6SA1
101603-4822  9 400 615 098  1156023712  INJECTION-PUMP ASSEMBLY
6SA1
101603-4830 
101603-4831 
  1156022741  INJECTION-PUMP ASSEMBLY
6BD1T
101603-4831  9 400 615 099  1156022742  INJECTION-PUMP ASSEMBLY
6BD1-T
101603-4840 
101603-4846 
  1156023032  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4841 
101603-4846 
  1156023033  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4842 
101603-4846 
  1156023034  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4843 
101603-4846 
  1156023035  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4844 
101603-4846 
  1156023036  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4845 
101603-4846 
  1156023037  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4846  9 400 615 100    INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

101603-4846  9 400 615 100  1156023038  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4850 
101603-4852 
  1156023720  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4851 
101603-4852 
  1156023721  INJECTION-PUMP ASSEMBLY
6BG1TC
101603-4852  9 400 615 101    INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

101603-4852  9 400 615 101  1156023722  INJECTION-PUMP ASSEMBLY
6BG1-TC
101603-4860 
101603-4861 
  1156024300  INJECTION-PUMP ASSEMBLY
6BG1N
101603-4861    1156024301  INJECTION-PUMP ASSEMBLY
6BG1N
101603-4870    1156024310  INJECTION-PUMP ASSEMBLY
6BG1S
101603-4880 
101603-4881 
  1156022602  INJECTION-PUMP ASSEMBLY
6BG1S
101603-4881  9 400 615 102  1156022603  INJECTION-PUMP ASSEMBLY
6BG1-S
101603-4890 
101603-4891 
  1156024320  INJECTION-PUMP ASSEMBLY
6BG1S
101603-4891    1156024321  INJECTION-PUMP ASSEMBLY
6BG1S
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