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


Information injection-pump assembly

BOSCH 9 400 615 238 9400615238
ZEXEL 101603-8040 1016038040
ISUZU 1156028120 1156028120

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:

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 Firm 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   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


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

Test data 101603-8040 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

Test data 101603-8040 F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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



Stop lever angle

Test data 101603-8040 N:Pump normal S:Stop the pump.
----------

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



0000001501 ACS

Test data 101603-8040 (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

Test data 101603-8040 (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)





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