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


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:

Cross reference number

BOSCH 9 400 615 258 9400615258
ZEXEL 101603-8310 1016038310
ISUZU 1156022900 1156022900


Zexel num Bosch num Firm num Firm 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   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


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

Test data 101603-8310 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

Test data 101603-8310 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

Test data 101603-8310 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

Test data 101603-8310 (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)





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101603-8301  9 400 615 257  8943947621  INJECTION-PUMP ASSEMBLY
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