101603-8270 ZEXEL 9 400 615 256 BOSCH INJECTION-PUMP ASSEMBLY 9400615256 1016038270 1156029110

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 256 9400615256

ZEXEL 101603-8270 1016038270

ISUZU 1156029110 1156029110

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Service parts 101603-8270 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4990

3. GOVERNOR 105931-9830

4. SUPPLY PUMP 105220-5920

5. AUTOM. ADVANCE MECHANIS 105644-0460

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6241

11. Nozzle and Holder 1-15300-142-1

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-5860

15. NOZZLE SET

Include in #1:

101491-0558 as _

101603-8270 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 256 9400615256

ZEXEL 101603-8270 1016038270

ISUZU 1156029110 1156029110

Zexel num

Bosch num

Firm num

Name

101603-8270

9 400 615 256

1156029110 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 K

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

Rack position
After adjusting injection quantity. R=A

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. 54.2 52.6 55.8

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. 8.4 7.1 9.7

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(10.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.2 53.2 55.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.6)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 66.8 63.6 70

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 87 87 119

Fixing the lever *

Timer adjustment

Pump speed r/min 1390--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1340

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1530

Advance angle deg. 3.5 3 4

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.
----------
T1=C78
----------

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=34deg+-5deg b=35deg+-3deg

Stop lever angle

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

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

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-2520 ST=A267 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

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=12deg
----------
a=(60deg)

Information:

start by: a) remove fuel injection lines 1. Remove cover (1) from the front of the timing gear cover. Remove bolt (2) and washer (3). Install bolt (2) again to the position shown. Use tool (A) to loosen the pump drive gear from the camshaft. Remove tool (A) and bolt (2).2. Remove the governor linkage. Disconnect the fuel supply line. 3. Remove inlet oil tube (4) for the turbocharger.4. Disconnect the air tube from the fuel ratio control.5. Disconnect hose (5).6. Disconnect the three drain tubes from the fuel injection pump housing.7. Remove bracket (6).8. Remove the three nuts that hold the fuel injection pump housing and governor to the timing plate.9. Remove the fuel injection pump housing and governor.Install Fuel Injection Pump Housing And Governor
1. Use the following procedures to put the No. 1 piston at top center on the compression stroke. No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures. The engine is seen from the flywheel end when direction of flywheel rotation is given.a) Turn the flywheel approximately 30 degrees clockwise. The reason for making this step is to be sure the play is removed from the timing gears when the engine is put on top center. b) For engines with a timing pointer, remove the cover on the flywheel housing. Turn the flywheel counterclockwise until the "TC 1" mark on the flywheel is in alignment with the pointer.c) For engines with a timing bolt, turn the flywheel counterclockwise until a 3/8-16 NC bolt can be installed in the flywheel through the hole in the flywheel housing. Do not turn the flywheel backwards.d) Remove the breather from the valve cover. The rocker arms for No. 1 piston can be seen through the breather hole in the valve cover.e) Check to see if both rocker arms for the No. 1 piston can be moved backward and forward by hand. The No. 1 piston is at top center on the compression stroke when the "TC 1" mark on the flywheel is in alignment with the pointer, or the bolt can be put in the flywheel through the hole in the flywheel housing, and both rocker arms for the No. 1 piston can be moved backward and forward by hand. f) If both rocker arms can not be moved by hand, the No. 1 piston is not at top center on the compression stroke. Turn the flywheel counterclockwise one full turn (360°). For engines with a timing pointer, the "TC 1" mark on the flywheel must then be in alignment with the pointer. For engines with a timing bolt, the bolt must be installed in the flywheel through the hole in the flywheel housing.2. For engines with a timing pointer, turn the flywheel counterclockwise until the pointer is between the 1° and 2° mark on the flywheel as shown. 3. For engines with a timing bolt, do not turn the flywheel past this position. 4. Remove the