101603-8571 ZEXEL 9 400 610 663 BOSCH INJECTION-PUMP ASSEMBLY 9400610663 1016038571 8943959041

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 663 9400610663

ZEXEL 101603-8571 1016038571

ISUZU 8943959041 8943959041

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Buy INJECTION-PUMP ASSEMBLY 101603-8571 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8571 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6240

3. GOVERNOR 105932-1120

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1140

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4531

11. Nozzle and Holder 8-94390-499-0

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-1000

15. NOZZLE SET

Include in #1:

101401-4151 as _

101603-8571 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 663 9400610663

ZEXEL 101603-8571 1016038571

ISUZU 8943959041 8943959041

Zexel num

Bosch num

Firm num

Name

101603-8571

9 400 610 663

8943959041 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-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 4.7 4.65 4.75

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 12.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 82 80.4 83.6

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 H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8.5 7.2 9.8

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(12.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 82 81 83

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 88.5 85.3 91.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 72.5 69.3 75.7

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 1400

Advance angle deg. 4.5 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.
----------
T1=K49
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=10deg+-5deg b=40deg+-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=131153-9020 ST=A769 L1=1mm L2=4.7+-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=6deg bb=R1(12.6)mm
----------
a=(150deg)

Information:

start by:a) remove air compressor 1. Remove elbow (1) and adapter. Remove the gasket, screen and gasket from behind the flange.2. Remove air compressor governor (2).3. Put a mark on the head assembly and block for correct assembly. 4. Remove six bolts (3). Remove head assembly (4). 5. Remove inlet valve springs (5) from the head assembly.6. Remove discharge valve seats (6). 7. Remove discharge valves (7). Remove springs from behind the valves. Check the discharge valve stops for wear or damage. If the discharge valve travel exceeds .057 in. (1.45 mm), make a replacement of the head assembly. 8. Remove inlet valves (8) from guides. Remove guides (9) from around the inlet valve seats. 9. Remove unloader spring (10), spring seat and spring saddle (12).10. Remove unloader plungers (11) and guides. 11. To remove unloader pistons (13) from the bore, put a cover over the inlet port, then blow air pressure in the governor mounting pad unloader port (14). 12. Check inlet valve seats (15) and unloader bore bushings (16) for damage or wear. If necessary, make a replacement. 13. Remove bolts (17). Remove cover (18) and gasket from the crankcase assembly.14. Put marks on the rod bearing caps and rods for correct assembly. 15. Remove bolts (19) and locks. Remove rod bearing caps (20). Push the pistons and rods through the top of the crankcase assembly. 16. Remove rod pin (21) from the piston. Remove rod (23).17. Remove bearings (22) from the rods and caps. 18. Use tooling (A) to remove bushing (24) from the rod. 19. Remove buttons (25) from each end of the rod pins. 20. Remove piston rings (26) from piston (27) with an approved ring expander. 21. Remove O-ring seal (29) from the crankshaft.22. Remove bolts (28). Remove adapter (30) from the crankcase assembly. 23. Remove three O-ring seals (32) from the adapter.24. Remove thrust bearing (31). 25. Use tooling (A) and a press to remove the bearing from the adapter.
Do not cause damage to the bearing surfaces of the crankshaft when it is removed from the crankcase assembly.
26. Remove crankshaft (33) from the crankcase assembly. 27. Remove bolts (34). Remove cover (35). Remove two O-ring seals from the crankcase assembly. 28. Remove O-ring seal (37) from the cover.29. Remove thrust bearing (36). 30. Remove bearing (38) from the cover.Assemble Air Compressor
1. Check all parts for damage or wear. If necessary, make a replacement with a new part.2. Make sure all parts are clean and free of dirt and foreign material. 3. Use tool (A) and a press to install the bearing in cover (1). 4. Install O-ring seal (3) on the cover.5. Install thrust bearing (2). 6. Install O-ring seals (4) in the crankcase assembly.7. Put a small amount of SAE 30 oil on the O-ring seal and install the cover on crankcase assembly (5). Tighten the bolts to a torque of 25 to 35 lb.ft. (35 to 45 N m). 8. Put crankshaft (6) in position in the crankcase assembly.