101603-7811 ZEXEL 9 400 615 216 BOSCH INJECTION-PUMP ASSEMBLY 9400615216 1016037811 1156027861


101603-7811 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 216 9400615216
ZEXEL 101603-7811 1016037811
ISUZU 1156027861 1156027861

Service parts 101603-7811 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4881
3. GOVERNOR 105931-8740
4. SUPPLY PUMP 105220-5930
5. AUTOM. ADVANCE MECHANIS 105644-0440
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5095
11. Nozzle and Holder 1-15300-266-4
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3862
14. NOZZLE 105017-1111
15. NOZZLE SET

Include in #1:

101603-7811 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 216 9400615216
ZEXEL 101603-7811 1016037811
ISUZU 1156027861 1156027861


Zexel num
Bosch num
Firm num
Name
101603-7811 
9 400 615 216 
1156027861  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-TC1 K

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   13.2
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.1 97.3
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   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(13.2)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   95.7 94.7 96.7
Basic   *
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.15
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   96.7 93.5 99.9
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 55)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   77 73.8 80.2
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.5
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   54 50.8 57.2
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   93 93 125
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R2-1.5
Boost pressure kPa   3.3 3.3 6
Boost pressure mmHg   25 25 45
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   R2(R1-0. 55)
Boost pressure kPa   21.3 21.3 21.3
Boost pressure mmHg   160 160 160
Timer adjustment
Pump speed r/min   (1170)
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1325
Advance angle deg.   1.5 1 2
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7811
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F36 BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 101603-7811
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39.5deg+-5deg b=(37deg)+-3deg

Stop lever angle

Test data 101603-7811
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=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7811
(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=10deg
----------
a=(60deg)




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