101603-8260 ZEXEL 9 400 615 255 BOSCH INJECTION-PUMP ASSEMBLY 9400615255 1016038260 1156029090

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 255 9400615255

ZEXEL 101603-8260 1016038260

ISUZU 1156029090 1156029090

Service parts 101603-8260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6130

3. GOVERNOR 105411-1670

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105644-0500

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7463

11. Nozzle and Holder 1-15300-307-3

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}

13. NOZZLE-HOLDER 105030-3231

14. NOZZLE 105015-9140

15. NOZZLE SET

Include in #1:

101491-0554 as _

101603-8260 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 255 9400615255

ZEXEL 101603-8260 1016038260

ISUZU 1156029090 1156029090

Zexel num

Bosch num

Firm num

Name

101603-8260

9 400 615 255

1156029090 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-MTC K 14BF INJECTION PUMP ASSY 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 105780-8140

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

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 A

Rack position 10.3

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 144.5 142.9 146.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 127 127

Boost pressure mmHg 950 950

Injection quantity adjustment_02

Adjusting point B

Rack position 4.4+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 13.5 12.2 14.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 8

Boost pressure kPa 40 37.3 42.7

Boost pressure mmHg 300 280 320

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position (10.3)

Boost pressure kPa 113 113 113

Boost pressure mmHg 850 850 850

Timer adjustment

Pump speed r/min 1350++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1350/

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Excess fuel lever does not operate. (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
----------
K=14 BCL=(2.3)+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(28deg)+-5deg b=(33deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=32deg+-5deg b=(55deg)

0000001101

N:Normal B:When boosted
----------

----------
a=(15deg) b=(30deg)

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=13deg
----------
a=(60deg)