101603-0962 ZEXEL 9 400 615 010 BOSCH INJECTION-PUMP ASSEMBLY 9400615010 1016030962 1156018985

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 010 9400615010

ZEXEL 101603-0962 1016030962

ISUZU 1156018985 1156018985

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Buy INJECTION-PUMP ASSEMBLY 101603-0962 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-0962 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4840

3. GOVERNOR 105931-6850

4. SUPPLY PUMP 105220-5910

5. AUTOM. ADVANCE MECHANIS 105612-3220

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder 5-15300-089-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101603-0962 as INJECTION-PUMP ASSEMBLY

101603-7711 as _

Cross reference number

BOSCH 9 400 615 010 9400615010

ZEXEL 101603-0962 1016030962

ISUZU 1156018985 1156018985

Zexel num

Bosch num

Firm num

Name

101603-0962

9 400 615 010

1156018985 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 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 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 3.6 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 -

Rack position 11.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 59.4 57.8 61

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 325 325 325

Average injection quantity mm3/st. 9.3 8 10.6

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(11.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 59.4 58.4 60.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.6)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 63.1 59.1 67.1

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 60.6 57.4 63.8

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 48.8 45.6 52

Fixing the lever *

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. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1600

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: RAL
----------
T1=E59 RAL=(13.5)+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
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=14deg
----------
a=(60deg)

Information:

Cleaning Primary Filter
Use all cleaning solutions with care.
1. Loosen the bolt (1) on the filter cover and lower the filter case (3).2. Remove the element (2). Wash the cover and element in clean, nonflammable solvent.3. Reinstall the element into the case.4. Install the element and case onto the cover.5. Tighten the bolt.Changing Secondary Filter
1. Unscrew filter element. Throw away the used element. 2. Make certain all of the used element seal is cleaned from the filter base. 3. Coat the seal of the new element with clean diesel fuel.
Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.
4. Install the filter by hand. When the seal contacts the base, tighten 3/4 turn more. There are rotation marks 90° apart on the filter. Use these as a guide for proper tightening.5. Start the engine and check for leaks. If the engine will not start, prime the fuel system.