Information injection-pump assembly
BOSCH
9 400 610 678
9400610678
ZEXEL
101603-8831
1016038831
ISUZU
8943900811
8943900811
Rating:
Service parts 101603-8831 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-498-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8831
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-5281
as _
Cross reference number
BOSCH
9 400 610 678
9400610678
ZEXEL
101603-8831
1016038831
ISUZU
8943900811
8943900811
Zexel num
Bosch num
Firm num
Name
101603-8831
9 400 610 678
8943900811 ISUZU
INJECTION-PUMP ASSEMBLY
6HH1 K 14BN INJECTION PUMP ASSY PE
6HH1 K 14BN INJECTION PUMP ASSY PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
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
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
Start
Timer adjustment_04
Pump speed
r/min
1425
Advance angle
deg.
5.5
5
6
Load
4/4
Remarks
Finish
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
----------
----------
T1=K97
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=11deg+-5deg b=38deg+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=38deg+-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
----------
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=7deg
----------
a=(150deg)
----------
aa=7deg
----------
a=(150deg)
Information:
TIMING SLOT PLUG (Typical Example)
1. Plug.2. Rotate the engine crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the timing slot in the fuel pump camshaft.3. Remove retaining screw (2) and washer (3) from end of engine camshaft.4. Remove automatic timing advance unit (4) from the camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
2. Retaining screw. 3. Washer. 4. Automatic timing advance unit.Install Automatic Timing Advance Unit
1. If timing mark on crankshaft gear and timing mark on camshaft gear are not aligned, rotate the crankshaft CLOCKWISE (as viewed from front of engine) until timing mark on crankshaft gear is aligned with timing mark on camshaft gear.
TIMING MARKS2. Align holes in weights with dowels in gear and install the automatic timing advance unit.3. Align pin (5) in washer with hole (6) in camshaft and install washer (3).
INSTALLING WASHER
3. Washer. 5. Pin. 6. Hole.4. Install retaining screw (2) and tighten to 108 36 lb. in. (124.5 41.5 cm.kg). Stake screw in two places.
STAKING SCREW (Typical Example)
2. Retaining screw.
Stake retaining screw (2) carefully. Heavy blows on washer or retaining screw can force the shaft extension too far into the camshaft and eliminate all end clearance.
5. After retaining screw (2) is staked, the gear and weight assembly requires .003 to .027 in. (0.08 to 0.69 mm) end clearance to prevent binding against the washer, camshaft end, or camshaft gear.
Have questions with 101603-8831?
Group cross 101603-8831 ZEXEL
Isuzu
101603-8831
9 400 610 678
8943900811
INJECTION-PUMP ASSEMBLY
6HH1
6HH1