101603-8130 ZEXEL 9 400 615 245 BOSCH INJECTION-PUMP ASSEMBLY 9400615245 1016038130 8943939730

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 245 9400615245

ZEXEL 101603-8130 1016038130

ISUZU 8943939730 8943939730

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Buy INJECTION-PUMP ASSEMBLY 101603-8130 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8130 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105931-9170

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0620

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5702

11. Nozzle and Holder 8-94394-787-1

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1090

15. NOZZLE SET

Include in #1:

101603-8130 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5240 as _

Cross reference number

BOSCH 9 400 615 245 9400615245

ZEXEL 101603-8130 1016038130

ISUZU 8943939730 8943939730

Zexel num

Bosch num

Firm num

Name

101603-8130

9 400 615 245

8943939730 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-S 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)
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 4.2 4.15 4.25

Rack position
After adjusting injection quantity. R=A

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 11.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.9 65.3 68.5

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 265 265 265

Average injection quantity mm3/st. 9 7.7 10.3

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(11.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 66.9 65.9 67.9

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. 78.5 74.5 82.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 49.7 46.5 52.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 99 99 131

Fixing the lever *

Timer adjustment

Pump speed r/min 1210--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1160

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

Load 4/4

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=G22
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=53mm
----------
a=11deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=62.5mm
----------
a=12.5deg+-5deg b=29deg+-5deg

0000001501 AIR CYLINDER

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
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0000001601 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=131153-4520 ST=A724 L1=1mm L2=4.2+-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)- (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Pointer stamping (9)Timing device stamping (10)Timing device (11)Stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg bb=1deg
----------
a=(150deg)

Information:

Firing order (injection sequence) ... 1, 5, 3, 6, 2, 4Injection timing before TC (top center) ... 12° 1°Injection timing before TC (top center) [aftercooled] ... 8° 30' 1°Torque for bolt in hole for timing pin ... 108 36 lb. in.(12.2 4.1 N m)Torque for bolts that hold governor weight carrier to camshaft ... 90 10 lb. in.(10.2 1.1 N m)(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 .0005 in.(60.249 0.013 mm) Bore in the rear bearing for the camshaft (new) ... 2.3750 .0005 in.(60.325 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .006 in.(0.15 mm)(2) Diameter of sleeve control shaft (new) ... .3530 .0003 in.(8.966 0.008 mm) Bore in the housing for the fuel control shaft (new) ... .3543 .0005 in.(8.999 0.013 mm)Maximum permissible clearance between the bore in the housing and the sleeve control shaft (worn) ... .003 in.(0.08 mm)(3) End play for camshaft with sleeve installed (new) ... .023 .018 in.(0.58 0.46 mm) When installing sleeve on end of camshaft, support the camshaft to prevent damage to parts inside of injection pump and governor housing.(4) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 .0005 in.(25.375 0.013 mm) Bore in the front bearing for the camshaft (new) ... 1.0005 .0005 in.(25.413 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .003 in.(0.08 mm) Install spring washer with bent side towards the governor spring (5) as shown.(5) Governor Spring: (6) Bypass valve: If the spring keeps the pressure in the fuel injection pump housing above 25 psi (170 kPa) with the engine operating under full load, the spring is good.Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 5 psi(205 35 kPa) Install guide pin (A) to depth (B) [.642 .003 in. (16.31 0.08 mm)]. Slot in guide pin (A) must be in area shown from center of lifter. (7) Torque for bushing ... 70 5 lb. ft.(95 7 N m)(8) 4N4318 Spring for injection pump: Length under test force ... 1.35 in.(34.3 mm)Test force ... 12.5 1.3 lb.(56 6 N)Free length after test ... 1.566 in.(39.78 mm)Outside diameter ... .728 in.(18.49 mm)(9) Torque for bolt holding sleeve on control shaft ... 24 2 lb. in.(2.8 0.2 N m) (10) Torque for the nuts that hold the fuel lines (Use 5P144 Fuel line Socket) ... 30 5 lb. ft.(40 7 N m)(11) Torque for the nuts that hold the nozzles ... 105 5 lb. ft.(142 7 N m)(12) Body.(13) Put 5P3931 Anti-Seize Compound on threads of glow plug and tighten to ... 120 24 lb. in.(13.6 2.8 N m)(14) Tighten nozzle finger tight on body.(15) Torque for precombustion chamber (put 5P3931 Anti-Seize Compound on threads)