101603-8611 ZEXEL 9 400 615 274 BOSCH INJECTION-PUMP ASSEMBLY 9400615274 1016038611 8943959031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 274 9400615274

ZEXEL 101603-8611 1016038611

ISUZU 8943959031 8943959031

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Buy INJECTION-PUMP ASSEMBLY 101603-8611 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8611 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6250

3. GOVERNOR 105932-1100

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1050

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4282

11. Nozzle and Holder 8-94395-511-1

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0530

15. NOZZLE SET

Include in #1:

101603-8611 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5482 as _

Cross reference number

BOSCH 9 400 615 274 9400615274

ZEXEL 101603-8611 1016038611

ISUZU 8943959031 8943959031

Zexel num

Bosch num

Firm num

Name

101603-8611

9 400 615 274

8943959031 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 4.2 4.15 4.25

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 10.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 71 69.4 72.6

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 275 275 275

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(10.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 71 70 72

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 87.5 83.5 91.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 57 53.8 60.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 125 125 133

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3 2.5 3.5

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=K77
----------

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 No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(160deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
New DEF sensor kits are available. The new sensor kit allows the DEF sensor to be repaired on DEF manifold assemblies.Note: If troubleshooting procedures indicate a replacement of the DEF manifold, do not replace the DEF Manifold. Repair the DEF Manifold using the DEF manifold sensor kit.Refer to Table 1 for the appropriate DEF sensor kit for the DEF manifold installed.
Table 1
DEF manifold Part Number Part Description Repair with DEF Sensor Kit
462-3219 11 inch (279mm) Manifold 593-0641
462-3610 13 inch (330mm) Manifold 593-0642
462-3232 18 inch (457mm) Manifold 593-0643
Illustration 1 g06508474New disassembly and assembly instructions are available. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Disassemble and Disassembly and Assembly, Manifold (DEF Heater) - Assemble for the correct procedures.