101603-7611 ZEXEL 9 400 619 600 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 619 600 9400619600
ZEXEL 101603-7611 1016037611
ISUZU 1156027601 1156027601

Service parts 101603-7611 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5140
3. GOVERNOR 105921-5690
4. SUPPLY PUMP 105210-5100
5. AUTOM. ADVANCE MECHANIS 105643-0790
6. COUPLING PLATE 105662-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6653
11. Nozzle and Holder 1-15300-288-3
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-9031
15. NOZZLE SET

Include in #1:

101603-7611 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 619 600 9400619600
ZEXEL 101603-7611 1016037611
ISUZU 1156027601 1156027601


Zexel num Bosch num Firm num Firm Name
101603-7611  9 400 619 600  1156027601  ISUZU INJECTION-PUMP ASSEMBLY
6SA1 * K

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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor 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   11.4
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   75 73.4 76.6
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   300 300 300
Average injection quantity mm3/st.   8.7 6.7 10.7
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(11.4)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   75 74 76
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.3
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   93.1 89.9 96.3
Fixing the lever   *


Injection quantity adjustment_05
Adjusting point   C
Rack position   R1(11.4)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   63.1 59.9 66.3
Fixing the lever   *


Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   106 106 116
Fixing the lever   *
Rack limit   *


Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks  
Start


Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5


Timer adjustment_03
Pump speed r/min   1200
Advance angle deg.   5 4.5 5.5
Remarks  
Finish

Test data Ex:



Governor adjustment

Test data 101603-7611 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G73
----------



Speed control lever angle

Test data 101603-7611 F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=34deg+-3deg



Stop lever angle

Test data 101603-7611 N:Pump normal S:Stop the pump.
----------

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



Timing setting

Test data 101603-7611 (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=16deg
----------
a=(40deg)





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Group cross 101603-7611 ZEXEL

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101603-7600 
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101603-7602 
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Isuzu 

101603-7690  9 400 615 206  1156026970  INJECTION-PUMP ASSEMBLY
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