101603-7032 ZEXEL 9 400 615 156 BOSCH INJECTION-PUMP ASSEMBLY 9400615156 1016037032


101603-7032 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 156 9400615156
ZEXEL 101603-7032 1016037032

Service parts 101603-7032 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4990
3. GOVERNOR 105931-4981
4. SUPPLY PUMP 105220-5920
5. AUTOM. ADVANCE MECHANIS 105644-0420
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6241
11. Nozzle and Holder 1-15300-142-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-5860
15. NOZZLE SET

Include in #1:

101603-7032 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 156 9400615156
ZEXEL 101603-7032 1016037032


Zexel num
Bosch num
Firm num
Name
101603-7032 
9 400 615 156 
   
INJECTION-PUMP ASSEMBLY
6BG1 * 14BE PE6A PE
101603-7032 
9 400 615 156 
1156024832  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 * 14BE 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   131424-4920
Overflow valve opening pressure kPa   127 107 147
Overflow valve opening pressure kgf/cm2   1.3 1.1 1.5
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
Rack position
After adjusting injection quantity.
  R=A
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.   54.2 52.6 55.8
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   290 290 290
Average injection quantity mm3/st.   8.4 7.1 9.7
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(10.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   54.2 53.2 55.2
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(10.6)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   66.8 63.6 70
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   87 87 119
Fixing the lever   *
Timer adjustment
Pump speed r/min   1390--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1340
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1530
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7032
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=C78
----------

Speed control lever angle

Test data 101603-7032
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg

Stop lever angle

Test data 101603-7032
N:Pump normal S:Stop the pump. (1)Stopper bolt setting
----------

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

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-2520 ST=A267 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 ACS

Test data 101603-7032
(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=900r/min L1=(1.5)mm L2=11+-0.5mm h1=0.15mm
----------
Ra=R1(10.6)mm Rb=R1-0.5mm Pa=84.5+-2.7kPa(634+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=54.2+-1cm3/1000st Q2=(39.8)+-1.6cm3/1000st

Timing setting

Test data 101603-7032
(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 101603-7032 ZEXEL

Isuzu 

 
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9 400 615 156 
 
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Isuzu 

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Isuzu 

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1156025151 
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6SA1-T
9 400 619 721 
1156025330 
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6SA1-T
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