101603-8440 ZEXEL 9 400 610 657 BOSCH INJECTION-PUMP ASSEMBLY 9400610657 1016038440 8943955821

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 657 9400610657

ZEXEL 101603-8440 1016038440

ISUZU 8943955821 8943955821

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Service parts 101603-8440 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105932-0740

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1030

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder 8-94393-335-1

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101603-8440 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5342 as _

Cross reference number

BOSCH 9 400 610 657 9400610657

ZEXEL 101603-8440 1016038440

ISUZU 8943955821 8943955821

Zexel num

Bosch num

Firm num

Name

101603-8440

9 400 610 657

8943955821 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-N 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 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 11.3

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77 75.4 78.6

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 -

Rack position 9.6+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77 76 78

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 77 73 81

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.3)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 66.5 63.3 69.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 127

Fixing the lever *

Timer adjustment

Pump speed r/min (1130)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 5.5 5 6

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=K10
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=37.5deg+-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

0000001501 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)At rack position = bb
----------
aa=5deg bb=11.3mm
----------
a=(150deg)

Information:

start by: a) remove flywheel housingb) remove crankshaft rear seal 1. Turn the crankshaft until the access holes in gears (1), (2) and (3) are in alignment with the nuts or bolts that hold the thrust washers to the timing gear plate. Turn the crankshaft more than one time if necessary to remove all of the nuts and bolts from the thrust washers. Do not remove any of the gears at this time.2. Turn the crankshaft to top center of compression stroke for No.1 piston. See LOCATING TOP CENTER FOR NO.1 PISTON in TESTING AND ADJUSTING.3. Install a 3/8"-16 NC eyebolt in drive shaft (6) and remove it from camshaft drive gear.
Do not turn crankshaft after drive shaft (6) or any of the gears are removed or damage to the pistons and valves will be the result.
4. Remove bolts (4), locks (5) and the hub from gear (7). 5. Remove the bolts, lock and washer to remove air compressor drive gear (8) from the timing gear plate. 6. Use tooling (A) and a press to remove the bearing from gear (8) as shown. 7. Remove gears (1), (2) and (3) and the thrust washers from the timing gear plate. 8. Use tooling (A) and a press to remove the bearings from gears (1), (2) and (3) as shown. 9. Turn gear (7) to make an alignment of the access holes in the gear with bolts (9). Remove the bolts, gear (7) and thrust washer from the timing gear plate. 10. Use tooling (A) and a press to remove the bearing from gear (7) as shown.Install Timing Gears
1. Use tooling (A) and a press to install the bearing in gear (1), until the bearing is even with the surface of the gear. 2. Install gear (1) and thrust washer (2) on the timing gear plate and tighten the bolts and locks to hold the thrust washer. 3. Use tooling (A) and a press to install the bearing in gear (3), until the bearing is even with the surface of the gear. 4. Use tooling (A) and a press to install the bearing in gear (4), until the bearing is even with the top surface of the gear as shown. 5. Put the bearing in position in compressor drive gear (5). Make sure that the reliefs in the bearing are in alignment with the reliefs in the gear. Use tooling (A) and a press to install the bearing even with the surface of gear (5) as shown. 6. Install the bearing in gear (6) with tooling (A) and a press until it is even with the surface of the gear.7. Make an alignment of the "V" mark on gear (3) with the "V" mark on the crankshaft gear and install gear (3) and the thrust washer on the timing gear plate. Tighten the bolts and lock to hold the thrust washer. 8. Make an alignment of the "V" mark on gear (4) with the "V" mark on gear (3) and