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

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 945 9400612945

ZEXEL 101603-8980 1016038980

ISUZU 1156032720 1156032720

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Buy INJECTION-PUMP ASSEMBLY 101603-8980 zexel genuine, new aftermarket engine parts with delivery

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)

Information:

FEED ENGAGED
21. Slot. 22. Pin. 23. Knob. To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).
LATER FEED MECHANISM
A. Lever.Place adapter (24) into boring bar and tighten setscrew (25).
ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 .0005 in. (94.425 0.013 mm).
BORING BEARING BORE
26. 1P2363 Universal. If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.
DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.The bluing applied to the bearing bore indicates the condition of the bore at the correct bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).
CHECKING BORE (Typical Example)Line Boring Main Bearing Bores
Line bore all main bearing bores if bearing caps or saddles are distorted.Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore. There must be two good bores for locating centering rings.
CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.
CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.
BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N m) and a maximum of 50 lb. ft. (70 N m) while spinning boring bar (5) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.
INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly