101603-4402 ZEXEL 9 400 610 649 BOSCH INJECTION-PUMP ASSEMBLY 9400610649 1016034402 1156022364


101603-4402 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 649 9400610649
ZEXEL 101603-4402 1016034402
ISUZU 1156022364 1156022364

Service parts 101603-4402 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4830
3. GOVERNOR 105932-2120
4. SUPPLY PUMP 105220-5910
5. AUTOM. ADVANCE MECHANIS 105612-3140
6. COUPLING PLATE 105661-0661
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5053
11. Nozzle and Holder 1-15300-105-2
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-4190
15. NOZZLE SET

Include in #1:

101603-4402 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 649 9400610649
ZEXEL 101603-4402 1016034402
ISUZU 1156022364 1156022364


Zexel num
Bosch num
Firm num
Name
101603-4402 
9 400 610 649 
1156022364  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1-T K 14BE INJECTION PUMP ASSY PE6A 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   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   3.4 3.35 3.45
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   -
Rack position   10.6
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   67 65.4 68.6
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   -
Rack position   9.6+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   67 66 68
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   74.5 71.3 77.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   (R1-0.4)
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   68.5 64.5 72.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.3
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   42.7 39.5 45.9
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   (R1-0.2)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   42.8 39.6 46
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   F
Rack position   (R1+0.15 )
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   42.4 39.2 45.6
Fixing the lever   *
Injection quantity adjustment_09
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   81 81 91
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   0.9 0.4 1.4
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4402
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E66
----------

Speed control lever angle

Test data 101603-4402
F:Full speed I:Idle (1)- (2)Stopper bolt set position 'H'
----------

----------
a=33deg+-5deg b=36deg+-3deg

Stop lever angle

Test data 101603-4402
N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

0000001501 ACS

Test data 101603-4402
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 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)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=900 r/min L1=(1.5) mm L2=11+-0.5 mm h1=0.15
----------
Ra=R1(10.6) mm Rb=R2(10.1) mm Pa=89.8+-2.7 kPa(674+-20 mmHg) Pb=70.1+-0.7 kPa(526+-5 mmHg) Q1=67+-1 cm3/1000st Q2=56.5+-1.6 cm3/1000st

Timing setting

Test data 101603-4402
(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=14deg
----------
a=(60deg)




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