101603-8721 ZEXEL 9 400 619 441 BOSCH INJECTION-PUMP ASSEMBLY 9400619441 1016038721 8943959762

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 441 9400619441

ZEXEL 101603-8721 1016038721

ISUZU 8943959762 8943959762

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Buy INJECTION-PUMP ASSEMBLY 101603-8721 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8721 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5490

3. GOVERNOR 105932-1221

4. SUPPLY PUMP 105210-6250

5. AUTOM. ADVANCE MECHANIS 105643-1060

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4282

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0530

15. NOZZLE SET

Include in #1:

101491-0557 as _

101603-8721 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 441 9400619441

ZEXEL 101603-8721 1016038721

ISUZU 8943959762 8943959762

Zexel num

Bosch num

Firm num

Name

101603-8721
101603-8722

9 400 619 441

8943959762 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 * 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 3.4 3.35 3.45

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 59 57.4 60.6

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(10.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 59 58 60

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 82 78.8 85.2

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. 49.8 46.6 53

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 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=K52
----------

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=14deg+-5deg b=38deg+-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 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=14deg
----------
a=(160deg)

Information:

Cylinder Head Removal And Installation
Refer to SERVICE GUIDE for Preliminary Information.
1-Water pipe. 2-Fan and pulley mounting bracket assembly. 3-Water bypass line. 4-Air compressor water return line.
5-Turbocharger-to-inlet manifold air pipe. 6-Turbocharger lubrication oil supply line. 7-Turbocharger oil drain line. 8-Exhaust elbow. 9-Turbocharger. 10-Fuel lines (six). 11-Valve cover. 12-Cylinder head.Cylinder Head Disassembly And Assembly
Refer to SERVICE GUIDE for Preliminary Information.5F8353 Wrench5S1330 Valve Spring Compressor Group7S8858 Valve Guide Driver Bushing7S8859 Valve Guide DriverFT192 Driver9M3710 Anti-Seize Compound8S3080 Tool Group9S3084 Extractor Head9S3087 Extractor HeadApply 9M3710 Anti-Seize Compound to threads. Tighten all head bolts (1, 2 and 3) in Step sequence shown. Use gaskets (6) to position precombustion chambers (4) to prevent wiring interference. Install thinnest gasket (6) first. Install precombustion chamber and tighten to specified torque. If the glow plug opening is not positioned in the "go" range, remove the chamber and replace gasket with that called for in the diagram.4 Use 5F8353 Wrench to remove and install chamber. Coat threads with 9M3710 Anti-Seize Compound.5 Coat seal and mating surface in bore with liquid soap.7 Align opening in water director with "V" mark on head.8 Gasket to be clean and dry at installation.9, 10 Tool required: 5S1330 Valve Spring Compressor Group. Assemble spring with painted end up.11 Tool required to remove valve guide: 7S8859 Valve Guide Driver. Tools required to install valve guide: 7S8859 Valve Guide Driver, 7S8858 Valve Guide Driver Bushing.12 Valve seat inserts can be removed and new inserts installed in the cylinder heads. Tools required to remove inserts: 9S3080 Tool Group, 9S3084 Extractor Head, 9S3087 Extractor Head.13 Tool required to install bearing: FT192 Driver. Align hole in bearing with hole in rocker arm.