101603-7730 ZEXEL 9 400 615 209 BOSCH INJECTION-PUMP ASSEMBLY 9400615209 1016037730 1156027761


101603-7730 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 209 9400615209
ZEXEL 101603-7730 1016037730
ISUZU 1156027761 1156027761

Service parts 101603-7730 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3420
3. GOVERNOR 105921-5580
4. SUPPLY PUMP 105210-5080
5. AUTOM. ADVANCE MECHANIS 105643-0340
6. COUPLING PLATE 105662-0430
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5301
11. Nozzle and Holder 1-15300-065-2
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105031-4771
14. NOZZLE 105015-4240
15. NOZZLE SET

Include in #1:

101603-7730 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 209 9400615209
ZEXEL 101603-7730 1016037730
ISUZU 1156027761 1156027761


Zexel num
Bosch num
Firm num
Name
101603-7730 
9 400 615 209 
1156027761  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1 K 14BE INJECTION PUMP ASSY 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 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)
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   3.2 3.15 3.25
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   12.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   92.7 91.1 94.3
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 7 11
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(12.2)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   92.7 91.7 93.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.2
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   103.2 100 106.4
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   (R1-0.15 )
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   84.4 81.2 87.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Each cylinder's injection qty mm3/st.   107 107 117
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1000
Advance angle deg.   1 0.5 1.5
Timer adjustment_04
Pump speed r/min   1200
Advance angle deg.   2.3 1.8 2.8
Timer adjustment_05
Pump speed r/min   1350
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7730
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D63
----------

Speed control lever angle

Test data 101603-7730
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101603-7730
N:Pump normal S:Stop the pump.
----------

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

0000001501 ACS

Test data 101603-7730
(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 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)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=700r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.2)mm Rb=(R1-1)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=92.7+-1cm3/1000st Q2=70+-1.6cm3/1000st

Timing setting

Test data 101603-7730
(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=20deg
----------
a=(40deg)




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