101603-8601 ZEXEL 9 400 610 666 BOSCH INJECTION-PUMP ASSEMBLY 9400610666 1016038601 8943959202

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 666 9400610666

ZEXEL 101603-8601 1016038601

ISUZU 8943959202 8943959202

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Buy INJECTION-PUMP ASSEMBLY 101603-8601 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8601 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6120

3. GOVERNOR 105932-1011

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-1070

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6092

11. Nozzle and Holder 8-94395-923-2

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE 105017-1900

15. NOZZLE SET

Include in #1:

101603-8601 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5471 as _

Cross reference number

BOSCH 9 400 610 666 9400610666

ZEXEL 101603-8601 1016038601

ISUZU 8943959202 8943959202

Zexel num

Bosch num

Firm num

Name

101603-8601
101603-8602

9 400 610 666

8943959202 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1TC-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 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)
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 3.5 3.45 3.55

Rack position
Point A 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 11.7

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. 10 8.7 11.3

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(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 82 81 83

Basic *

Fixing the lever *

Boost pressure kPa 45.3 45.3

Boost pressure mmHg 340 340

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 87.5 84.3 90.7

Fixing the lever *

Boost pressure kPa 45.3 45.3

Boost pressure mmHg 340 340

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.8

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 68.5 65.3 71.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 105 105 137

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 850 850 850

Rack position R1-0.8

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 850 850 850

Rack position R1(11.7)

Boost pressure kPa 32 25.3 38.7

Boost pressure mmHg 240 190 290

Timer adjustment

Pump speed r/min 1175--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1125

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Load 4/4

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)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost. (4)Boost compensator stroke: BCL
----------
T1=K57 Ra=12+-0.5mm BCL=0.8+-0.1mm
----------

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=12deg+-5deg b=35deg+-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 the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=9deg
----------
a=(150deg)

Information:

start by:a) separation of governor from fuel injection pump housing 1. Remove the protection caps and felt washers (1) from pumps.2. Use wrench (A) to remove bushings (2) that hold the fuel injection pumps into the housing. Remove seals (3).3. Use extractor (B) to remove the pumps from the pump housing. Put identification on the injection pumps as to their location in the pump housing.4. Remove bonnet (4), ring (5), spring (6) and check valve (7) from barrel (8).5. Remove plunger assembly (11), washer (10) and spring (9) from the barrel.
Be careful not to cause damage to plunger assemblies. Keep the same cylinder pump and plunger together, the plunger from one pump can not be installed in another group.
6. Remove rack (12) from the housing. 7. Remove spacers (13) and lifters (14) from the housing. Keep the spacers and lifters together with identification as to their location in the pump housing. 8. Remove two bolts (16), lock and two sleeves from the gear assembly.9. Remove gear assembly (15) from the camshaft. 10. Remove two bolts, plate (17) and the spacer that hold the camshaft in position in the pump housing. 11. Remove the camshaft from the pump housing. 12. Use tool group (C) to remove the camshaft bearings from the pump housing.13. Remove the bearings for the fuel rack from the pump housing.Assemble Fuel Injection Pump Housing
1. Use tooling (C) to install the camshaft bearings in the fuel injection pump housing. Install the camshaft bearing joints 15° from the vertical centerline of the bores. Install the front and rear camshaft bearings even with the fuel injection pump housing. Install the center camshaft bearing a distance of 4.81 .02 in. (122.2 0.5 mm) from the rear face of the fuel injection pump housing. 2. Use tooling (F) to install the bearing with a tab for the groove in the rack.3. Use tooling (E) to install the rear bearing for the rack. Install the bearing to a depth of .282 .005 in. (7.16 0.13 mm). The small holes in the rear bearing must be installed parallel to the vertical centerline of the pump. 4. Put clean engine oil on the camshaft. Install the camshaft in the pump housing. 5. Install the spacer, plate (1) and two bolts that hold the camshaft in place in the pump housing. 6. Put gear assembly (2) in position on the end of the camshaft. Be sure rod (3) is in the groove of the camshaft. 7. Install sleeves (4), lock and two bolts on the gear assembly. 8. Install spacers (5) with their respective lifters (6) in the pump housing. If new lifters and/or pumps are to be installed, make adjustment of the fuel pump timing dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION: OFF ENGINE TESTING AND ADJUSTING. 9. Install rack (7) in the pump housing.10. Assemble the fuel injection pumps as follows: a) Put clean fuel on all parts.b) Install the spring, washers and plunger in the