101603-8581 ZEXEL 9 400 610 664 BOSCH INJECTION-PUMP ASSEMBLY 9400610664 1016038581 8943959052

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 664 9400610664

ZEXEL 101603-8581 1016038581

ISUZU 8943959052 8943959052

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Buy INJECTION-PUMP ASSEMBLY 101603-8581 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8581 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6240

3. GOVERNOR 105932-1070

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:

101603-8581 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-5220 as _

Cross reference number

BOSCH 9 400 610 664 9400610664

ZEXEL 101603-8581 1016038581

ISUZU 8943959052 8943959052

Zexel num

Bosch num

Firm num

Name

101603-8581

9 400 610 664

8943959052 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-N K

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 12.1

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 70.9 74.1

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(12.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(12.1)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 74.5 70.5 78.5

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4.5 4.5 4.5

Remarks
Measure the actual speed, stop

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=L58
----------

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=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(12.1)mm
----------
a=(150deg)

Information:

start by:a) remove fuel transfer pump 1. Remove bolts (1). Remove cover (2) from the fuel transfer pump. 2. Remove bolt (3). Remove gasket, spring and plunger from under bolt.3. Remove gear (4).4. Remove shaft assembly (5). 5. Remove O-ring seal (7) from body assembly.6. Install a 5/16"-18 NC forged eyebolt (6) in the plug. Remove plug (8) and O-ring seal. Remove the O-ring seal from the plug. 7. Remove valve assembly (9). 8. Remove two lip seals (10) from the body assembly. 9. Remove two bearings (11) from the body assembly with tooling (A).Assemble Fuel Transfer Pump (Later)
1. Install bearings in body (1) with tooling (A). Install bearing on gear end of body to a depth of .03 .02 in. (0.76 0.51 mm) below the surface of the body. Install the bearing on the opposite end of the body even with the body surface. 2. Put 4H5363 Sealant on the outside diameters of the seals. Install the lip seals in the body assembly with tooling (A). Install the first seal with lip toward bearing. Install the lip seal to a depth of .406 .010 (10.31 0.25 mm). Install the second seal with lip away from bearing. Make sure the second lip seal is even with the surface of the body assembly. 3. Install the valve assembly in the body assembly with tooling (A) to a depth of .57 .02 in. (14.5 0.5 mm). 4. Install O-ring seal (3) on the plug. Install a 5/16"-18 NC forged eyebolt (2) in the plug. Put a small amount of clean diesel fuel on the O-ring seal and install plug (4) in the body assembly. Make sure plug is even with the surface of the body.5. Install O-ring seal on the body assembly. 6. Put a small amount of clean diesel fuel on the lip seals. Put tool (B) in position on shaft assembly. Install shaft assembly (5) in the body assembly. 7. Install gear (7).
Do not get liquid gasket material into pump.
8. Put 7M7260 Liquid Gasket Material on the body assembly surface that makes contact with the cover. Install cover (6).9. Shaft assembly must turn by hand after cover is installed. 10. Install plunger (8), spring (9), gasket (11) and plug (10) in body assembly. Tighten plug to a torque of 27 3 lb. ft. (38 4 N m).end by:a) install fuel transfer pump