101603-8850 ZEXEL 9 400 610 680 BOSCH INJECTION-PUMP ASSEMBLY 9400610680 1016038850 1156031400


101603-8850 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 680 9400610680
ZEXEL 101603-8850 1016038850
ISUZU 1156031400 1156031400

Service parts 101603-8850 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6450
3. GOVERNOR 105411-1830
4. SUPPLY PUMP 105220-6240
5. AUTOM. ADVANCE MECHANIS 105644-0560
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-4170
11. Nozzle and Holder 1-15300-331-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-4361
14. NOZZLE 105025-0290
15. NOZZLE SET

Include in #1:

101603-8850 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 680 9400610680
ZEXEL 101603-8850 1016038850
ISUZU 1156031400 1156031400


Zexel num
Bosch num
Firm num
Name
101603-8850 
9 400 610 680 
1156031400  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1-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)
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   10.9
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   98.5 97 100
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   66.7 66.7
Boost pressure mmHg   500 500
Injection quantity adjustment_02
Adjusting point   C
Rack position   6.4+-0.5
Pump speed r/min   415 415 415
Average injection quantity mm3/st.   9 7.7 10.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_03
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   110 105 115
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R1-1.1
Boost pressure kPa   13.3 10.6 16
Boost pressure mmHg   100 80 120
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(10.9)
Boost pressure kPa   53.3 46.6 60
Boost pressure mmHg   400 350 450
Timer adjustment
Pump speed r/min   1300++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1300.
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   5.5 5.5 5.5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101603-8850
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
----------
K=9 BCL=1.1+-0.1mm
----------

Speed control lever angle

Test data 101603-8850
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=6deg+-5deg b=23deg+-5deg

Stop lever angle

Test data 101603-8850
N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)

Timing setting

Test data 101603-8850
(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=12deg
----------
a=(60deg)




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