101603-8663 ZEXEL 9 400 613 120 BOSCH INJECTION-PUMP ASSEMBLY 9400613120 1016038663 8943959804

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 120 9400613120

ZEXEL 101603-8663 1016038663

ISUZU 8943959804 8943959804

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101492-0513 as _

Cross reference number

BOSCH 9 400 613 120 9400613120

ZEXEL 101603-8663 1016038663

ISUZU 8943959804 8943959804

Zexel num

Bosch num

Firm num

Name

101603-8663

9 400 613 120

8943959804 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.
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T1=K49
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=35mm
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a=14deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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.
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PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
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0000001601 AIR CYLINDER

(a) Air cylinder (b) Speed lever (c) Lock nut 1. Air cylinder adjustment procedure (1)Fix the speed lever (b) at the idle side. (2)Screw in the air cylinder (a) (3)Set the clearance between the speed lever (b) and the air cylinder (a) to approximately L1.
----------
L1=1mm
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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:

3. Remove nuts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rod from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners.
Never install the ring compressor on the piston unless the cylinder liner is used as a guide. Damage to the piston rings can be the result.
2. Use tool (A) and install pistons (1) and connecting rods in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.3. Install the bearing caps on the connecting rods with number on side of the bearing caps on the same side and same number as on the connecting rod.4. Install the nuts and tighten to a torque of 60 6 lb.ft. (80 8 N m). Put a mark on the nuts and caps and tighten nuts an extra 120°.5. Do Steps 1 through 4 for the remainder of the pistons.end by:a) install oil pumpb) install cylinder headDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove bearings (2) from the connecting rod and connecting rod cap.2. Remove retainer ring (1). Remove piston pin (3) from the piston and connecting rod. 3. Use tool (A) to remove the piston rings (4) from the piston. 4. Heat the connecting rod to a temperature of 350 to 500°F (177 to 260°C). Put connecting rod (6) in position on the base plate of tooling (B). Put a new bearing (5) on the adapter of tooling (B). Put the adapter in position in the connecting rod and base plate of tooling (B). 5. Install the pusher adapter (8) and pusher (7) from tooling (B) on the adapter. The old bearing is pushed out by tooling (B) as the new bearing is installed.6. Use tooling (B) to push the new bearing (5) into the connecting rod (6) until the push adapter of tooling (B) makes full contact with the connecting rod surface. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTION, Form No. SMHS7295. Use tooling (C) for later type connecting rods (tapered ends).7. Check the piston pin bore diameter after the bearing is installed. The correct dimension is 2.0012 .0003 in. (50.830 0.008 mm).8. Clean the ring grooves in the piston before rings are installed. The two compression rings have marks "UP-1" and "UP-2". The rings must be installed with these marks toward the top of the piston with "UP-1" as the top ring. After installation of all three piston rings, put piston rings in position so gaps in rings are 120° apart. 9. Use tool (A) to install the piston rings on the piston. 10. Install bearings (2) in the connecting rod and connecting rod cap. Be sure the tabs in back of bearings are in the tab