101603-7821 ZEXEL 9 400 615 217 BOSCH INJECTION-PUMP ASSEMBLY 9400615217 1016037821 1156027931

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 217 9400615217

ZEXEL 101603-7821 1016037821

ISUZU 1156027931 1156027931

Service parts 101603-7821 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4941

3. GOVERNOR 105931-8750

4. SUPPLY PUMP 105220-5970

5. AUTOM. ADVANCE MECHANIS 105644-0450

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:

101492-0570 as _

101603-7821 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 217 9400615217

ZEXEL 101603-7821 1016037821

ISUZU 1156027931 1156027931

Zexel num

Bosch num

Firm num

Name

101603-7821

9 400 615 217

1156027931 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TC2 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 4.9 4.85 4.95

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

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87.7 86.1 89.3

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)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 87.7 86.7 88.7

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 95.5 92.3 98.7

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 5)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 72.8 69.6 76

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_06

Adjusting point D

Rack position R2-1.35

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. 96 96 128

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 R2-1.35

Boost pressure kPa 4 4 6.7

Boost pressure mmHg 30 30 50

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 5)

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

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=F37 BCL=1.35+-0.1mm
----------

Speed control lever angle

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=39deg+-3deg

Stop lever angle

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=131153-5520 ST=A734 L1=1mm L2=4.9+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(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=11deg
----------
a=(60deg)