101603-7402 ZEXEL 9 400 615 179 BOSCH INJECTION-PUMP ASSEMBLY 9400615179 1016037402 1156026592


101603-7402 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 179 9400615179
ZEXEL 101603-7402 1016037402
ISUZU 1156026592 1156026592

Service parts 101603-7402 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3960
3. GOVERNOR 105921-4302
4. SUPPLY PUMP 105210-4930
5. AUTOM. ADVANCE MECHANIS 105672-5010
6. COUPLING PLATE 105662-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6233
11. Nozzle and Holder 1-15300-276-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-8391
15. NOZZLE SET

Include in #1:

101603-7402 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 179 9400615179
ZEXEL 101603-7402 1016037402
ISUZU 1156026592 1156026592


Zexel num
Bosch num
Firm num
Name
101603-7402 
9 400 615 179 
1156026592  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1 * K 14BF 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   105780-8210
Nozzle   105780-0070
Bosch type code   DN12SD12T-1
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Rack position
After adjusting injection quantity.
  R=A
Beginning of injection position
Governor 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   12.3
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   79 77.4 80.6
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   H
Rack position   9.5+-0.5
Pump speed r/min   260 260 260
Average injection quantity mm3/st.   9.1 7.1 11.1
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(12.3)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   79 78 80
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.1
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   92.2 89 95.4
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   121 121 153
Fixing the lever   *
Timer adjustment
Pump speed r/min   900--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   850
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   (900)
Advance angle deg.   1 0.4 1
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1150
Advance angle deg.   1.7 1.2 2.2
Timer adjustment_05
Pump speed r/min   1300
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7402
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=F25
----------

Speed control lever angle

Test data 101603-7402
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=20deg+-5deg b=(39deg)+-3deg

Stop lever angle

Test data 101603-7402
N:Pump normal S:Stop the pump.
----------

----------
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=131153-5620 ST=A735 L1=1mm L2=3.7+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7402
(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=8.5deg
----------
a=(40deg)




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