101603-8310 ZEXEL 9 400 615 258 BOSCH INJECTION-PUMP ASSEMBLY 9400615258 1016038310 1156022900

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 258 9400615258

ZEXEL 101603-8310 1016038310

ISUZU 1156022900 1156022900

Service parts 101603-8310 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3301

3. GOVERNOR 105921-7270

4. SUPPLY PUMP 105210-5100

5. AUTOM. ADVANCE MECHANIS 105643-0210

6. COUPLING PLATE 105662-0430

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6111

11. Nozzle and Holder 1-15300-251-1

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-8260

15. NOZZLE SET

Include in #1:

101603-8310 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1402 as _

Cross reference number

BOSCH 9 400 615 258 9400615258

ZEXEL 101603-8310 1016038310

ISUZU 1156022900 1156022900

Zexel num

Bosch num

Firm num

Name

101603-8310

9 400 615 258

1156022900 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1-T 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)
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 3.7 3.65 3.75

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 12.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 109.5 107.9 111.1

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 290 290 290

Average injection quantity mm3/st. 9.9 7.9 11.9

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(12.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 109.5 108.5 110.5

Basic *

Fixing the lever *

Boost pressure kPa 81.3 81.3

Boost pressure mmHg 610 610

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.45

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 103.5 100.3 106.7

Fixing the lever *

Boost pressure kPa 81.3 81.3

Boost pressure mmHg 610 610

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.95

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 87 83 91

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 98 98 108

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 900 900 900

Rack position R1-0.95

Boost pressure kPa 45.3 44 46.6

Boost pressure mmHg 340 330 350

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Rack position R1(12.6)

Boost pressure kPa 68 61.3 74.7

Boost pressure mmHg 510 460 560

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 2 1.5 2.5

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)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=J22 BCL=0.95+-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=35.5mm
----------
a=18deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=45mm
----------
a=25deg+-5deg b=40deg+-5deg

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=15deg
----------
a=(40deg)