101603-8150 ZEXEL 9 400 615 247 BOSCH INJECTION-PUMP ASSEMBLY 9400615247 1016038150 1156027610

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 247 9400615247

ZEXEL 101603-8150 1016038150

ISUZU 1156027610 1156027610

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Buy INJECTION-PUMP ASSEMBLY 101603-8150 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5140

3. GOVERNOR 105921-6250

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:

101603-8150 as INJECTION-PUMP ASSEMBLY

Include in #2:

104136-3030 as _

Cross reference number

BOSCH 9 400 615 247 9400615247

ZEXEL 101603-8150 1016038150

ISUZU 1156027610 1156027610

Zexel num

Bosch num

Firm num

Name

101603-8150

9 400 615 247

1156027610 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:

(1) Thickness of spacer plate ... .3925 .0010 in.(9.970 0.025 mm) Thickness of spacer plate gasket ... .0082 .0010 in.(0.208 0.025 mm) For height of liner over top of spacer plate make reference to CYLINDER LINER PROJECTION.(2) Camshaft bearing bore (installed) ... 2.3150 .0020 in.(58.801 0.051 mm) Bore in block for camshaft bearings ... 2.5630 .0010 in.(65.100 0.025 mm)Depth to install camshaft bearings at both ends of block ... .06 .02 in.(1.5 0.5 mm) The camshaft bearing at the front of the block must be installed with oil holes in a horizontal position and joint at top within 15° from vertical.(3) Bore in block for main bearings (standard size) (with main bearing caps torqued) ... 3.8160 .0005 in.(96.926 0.013 mm) Bore in block for main bearings .020 in. (0.51 mm oversize) ... 3.8360 .0005 in.(97.434 0.013 mm)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 15.099 .006 in.(383.51 0.15 mm)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 6.063 .004 in.(154.00 0.10 mm)(6) Torque for bolts holding bearing caps for main bearings: a. Put engine oil on threads and washer face.b. Tighten all bolts to ... 30 3 lb. ft.(40 4 N m)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90° Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between slot in block and bearing cap (with main bearing caps torqued) ... .0017 in.(0.043 mm) loose to ... .0013 in.(0.033 mm) tight
There are holes in the bores for the main bearings, between the cylinders for piston cooler orifices. These holes must have orifices (8) installed.