101603-8040 ZEXEL 9 400 615 238 BOSCH INJECTION-PUMP ASSEMBLY 9400615238 1016038040 1156028120

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 238 9400615238

ZEXEL 101603-8040 1016038040

ISUZU 1156028120 1156028120

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Buy INJECTION-PUMP ASSEMBLY 101603-8040 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5140

3. GOVERNOR 105921-5900

4. SUPPLY PUMP 105210-5100

5. AUTOM. ADVANCE MECHANIS 105643-0790

6. COUPLING PLATE 105662-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6653

11. Nozzle and Holder 1-15300-288-3

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-9031

15. NOZZLE SET

Include in #1:

101401-4132 as _

101603-8040 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 238 9400615238

ZEXEL 101603-8040 1016038040

ISUZU 1156028120 1156028120

Zexel num

Bosch num

Firm num

Name

101603-8040

9 400 615 238

1156028120 ISUZU

INJECTION-PUMP ASSEMBLY
6SA1 * K 14BF INJECTION PUMP ASSY PE6AD 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)
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 11.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 69.4 67.8 71

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 300 300 300

Average injection quantity mm3/st. 8.7 6.7 10.7

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(11.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 69.4 68.4 70.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 89 85.8 92.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.3)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 56.7 53.5 59.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 106 106 116

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 1200

Advance angle deg. 5 4.5 5.5

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=G73
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=34deg+-3deg

Stop lever angle

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

----------
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)(C) Turn the screw to adjust the beginning 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)Adjust using 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=700r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(11.3)mm Rb=(R1-0.6)mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=69.4+-1cm3/1000st Q2=50+-1.6cm3/1000st

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=16deg
----------
a=(40deg)

Information:

start by:a) remove automatic timing advanceb) remove vibration damper and pulleyc) remove water pumpd) remove belt tightener idler pulleye) remove water temperature regulator (left cylinder head)1. Remove the tube assembly from the oil cooler elbow to the oil pan.2. Loosen the bolts that hold the oil pan to the cylinder block approximately 1/4" (6.4 mm). Remove the bolts that hold the oil pan to the timing gear cover.3. Fasten a hoist to the engine and lift it off tool (A). Weight of the engine is 3200 lb. (1452 kg). Make a separation of the oil pan from the cylinder block and timing gear cover. Do not damage the pan gasket.4. Put 1/4" (6.4 mm) pieces of bar stock between the pan and cylinder block at the positions the oil pan makes contact with tool (A). Lower the engine on tool (A).5. Remove the bolts from the belt tightener bracket. Remove the block and gasket. 6. Remove fumes disposal tube (1).7. Remove the bolts (4) that hold the timing gear cover to the cylinder block.8. Remove water bonnet (2).9. Remove timing gear cover (3).
Do not cause damage to the crankshaft front seal when the cover is removed.
10. Check the condition of the O-ring seal on the fuel injection pump housing.Install Timing Gear Cover
1. Put clean engine oil on the O-ring seal for the fuel injection pump housing, the crankshaft front seal and wear sleeve.2. Install tool (B) in the crankshaft front seal.3. Install a new gasket on the timing gear cover. Put timing gear cover (1) in position on the dowels in the cylinder block. Make sure it is against the cylinder block all around.4. Install the bolts that hold the cover in position. Remove tool (B) from the crankshaft front seal.5. Install the water bonnet, the fumes disposal tube and the block for the belt tightener bracket.6. Fasten a hoist to the engine and lift it off tool (A). Remove the bar stock from between the cylinder block and oil pan. Tighten the bolts that hold the oil pan to the cylinder block.7. Install the bolts that hold the oil pan to the timing gear cover. Put the engine back on tool (A).8. Install the tube assembly between the oil pan and oil cooler.end by:a) install water temperature regulator (left cylinder head)b) install belt tightener idler pulleyc) install water pumpd) install vibration damper and pulleye) install automatic timing advance