101603-8683 ZEXEL 9 400 612 259 BOSCH INJECTION-PUMP ASSEMBLY 9400612259 1016038683 8943959693

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 259 9400612259

ZEXEL 101603-8683 1016038683

ISUZU 8943959693 8943959693

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-8683 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8683 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6330

3. GOVERNOR 105932-1282

4. SUPPLY PUMP 105210-6090

5. AUTOM. ADVANCE MECHANIS 105672-5290

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4292

11. Nozzle and Holder 8-94395-498-2

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0580

15. NOZZLE SET

Include in #1:

101491-0537 as _

101603-8683 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 259 9400612259

ZEXEL 101603-8683 1016038683

ISUZU 8943959693 8943959693

Zexel num

Bosch num

Firm num

Name

101603-8683

9 400 612 259

8943959693 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 K 14BN INJECTION PUMP ASSY PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.95 4.05

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 11.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 89.9 93.1

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 Z

Rack position 9.6+-0.5

Pump speed r/min 240 240 240

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 *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 90.5 92.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.95

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 100.5 96.5 104.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.6

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 98.5 94.5 102.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 130 130 138

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 0/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 0/4

Timer adjustment_03

Pump speed r/min (900)

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_04

Pump speed r/min 1425

Advance angle deg. 5.5 5 6

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)RACK LIMIT
----------
T1=K97
----------

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=13deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

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=7deg
----------
a=(150deg)

Information:

Remove Brakesaver
start by:a) remove flywheel (BrakeSaver) 1. Disconnect BrakeSaver lubrication oil line (1) from the fitting in the BrakeSaver housing. 2. Disconnect the oil line from fitting (5).3. Remove two short bolts (2) and two longer bolts (4) that hold manifold (3) to the BrakeSaver housing. Remove manifold (3) from the BrakeSaver control valve.4. Remove the O-ring seals from the manifold. The two longer bolts (4) from the manifold can be used as forcing screws to remove the BrakeSaver from the flywheel housing.5. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist. 6. Install tooling (A) on the BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at removal. This prevents damage to the rotor rings and seals.7. Remove bolts (6) that hold BrakeSaver housing (7) to the flywheel housing.8. Use bolts (4) as forcing screws and tighten the bolts evenly to remove BrakeSaver housing (7) from the flywheel housing. The weight is 190 lb. (86 kg).Install Brakesaver
1. Install tooling (A) on BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at installation. This prevents damage to the rotor rings and seals.2. Install a 3/8"-16 NC forged eyebolt in the top of the BrakeSaver housing and fasten a hoist.3. Install two 5/8"-18 guide pins (3) in the crankshaft as shown. Make sure dowel (2) is in alignment with the dowel hole in the rotor assembly and put BrakeSaver housing (1) in position in the flywheel housing.4. Install the three bolts that hold the BrakeSaver housing to the flywheel housing. Remove tooling (A) and guide pins (3). 5. Connect the oil line to fitting (6).6. Inspect the O-ring seals for damage and make replacements if needed. Install O-ring seals (4) and (5). Put clean oil on the O-ring seals.7. Install manifold (7) into the BrakeSaver control valve and install the four bolts that hold the manifold to the BrakeSaver housing. 8. Connect BrakeSaver lubrication oil line (8) to the fitting in the BrakeSaver housing.end by:a) install flywheel (BrakeSaver)Disassemble Brakesaver
start by:a) remove BrakeSaver1. Remove tooling (A) from the BrakeSaver housing and rotor. Tooling (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver housing. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator. 4. Turn the stator over and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve. 6. Remove O-ring seal (11) and the six smaller O-ring seals from the oil holes on the housing.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly