101603-7832 ZEXEL 9 400 615 218 BOSCH INJECTION-PUMP ASSEMBLY 9400615218 1016037832 8943934592

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 218 9400615218

ZEXEL 101603-7832 1016037832

ISUZU 8943934592 8943934592

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-7832 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7832 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6080

3. GOVERNOR 105931-8772

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0810

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:

101603-7832 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6930 as _

Cross reference number

BOSCH 9 400 615 218 9400615218

ZEXEL 101603-7832 1016037832

ISUZU 8943934592 8943934592

Zexel num

Bosch num

Firm num

Name

101603-7832

9 400 615 218

8943934592 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-S 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 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 3.6 3.55 3.65

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 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.7 76.1 79.3

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. 8.8 7.5 10.1

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(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.7 76.7 78.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 94.6 90.6 98.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 60.9 57.7 64.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 96 96 104

Fixing the lever *

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

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=H33
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

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=14deg
----------
a=(150deg)

Information:

(1) Nut (4K0367)(2) Bearing (9U6877)(3) Washer (5P8247)(4) Bridge plate (9U7259)(5) Bolts (5/16)(6) Threaded rod puller stud (221-9778)(7) Threaded end
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and