101603-8980 ZEXEL 9 400 612 945 BOSCH INJECTION-PUMP ASSEMBLY 9400612945 1016038980 1156032720

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 945 9400612945

ZEXEL 101603-8980 1016038980

ISUZU 1156032720 1156032720

Service parts 101603-8980 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3880

3. GOVERNOR 105921-8220

4. SUPPLY PUMP 105210-5100

5. AUTOM. ADVANCE MECHANIS 105643-0650

6. COUPLING PLATE 105662-1560

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6301

11. Nozzle and Holder 1-15300-263-1

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

13. NOZZLE-HOLDER 105030-4351

14. NOZZLE

105015-8640

15. NOZZLE SET

Include in #1:

101401-4302 as _

101603-8980 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 945 9400612945

ZEXEL 101603-8980 1016038980

ISUZU 1156032720 1156032720

Zexel num

Bosch num

Firm num

Name

101603-8980

9 400 612 945

1156032720 ISUZU

INJECTION-PUMP ASSEMBLY
6SD1 K 14BF INJECTION PUMP ASSY PE6AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 35 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 11.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 89.8 88.2 91.4

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. 11.2 9.2 13.2

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(11.9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 89.8 88.8 90.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 88 88 93

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 4 3.5 4.5

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
----------
T1=K80
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35.5mm
----------
a=18deg+-5deg b=36deg+-3deg

Stop lever angle

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

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)Turn adjusting screw (C) to adjust the start of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Turn adjusting screw (C) to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=650r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=0.1~0.5mm
----------
Ra=R1(11.9)mm Rb=(R1-0.4)mm Rc=(R1-1.1)mm Pa=90.6+-2.7kPa(680+-20mmHg) Pb=82.5+-0.7kPa(619+-5mmHg) Pc=(70.1)kPa((526)mmHg) Q1=89.8+-1cm3/1000st Q2=81.5+-1cm3/1000st Q3=(66.5)cm3/1000st

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(40deg)