101603-8860 ZEXEL 9 400 610 681 BOSCH INJECTION-PUMP ASSEMBLY 9400610681 1016038860 8943909610

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 681 9400610681

ZEXEL 101603-8860 1016038860

ISUZU 8943909610 8943909610

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Buy INJECTION-PUMP ASSEMBLY 101603-8860 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8860 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6250

3. GOVERNOR 105932-2080

4. SUPPLY PUMP 105210-6090

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:

101401-4254 as _

101603-8860 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 681 9400610681

ZEXEL 101603-8860 1016038860

ISUZU 8943909610 8943909610

Zexel num

Bosch num

Firm num

Name

101603-8860
101603-8861

9 400 610 681

8943909610 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 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 hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=14deg+-5deg b=35deg+-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

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:

TIMING PIN HOLE PLUG (Typical Example)
1. Plug.2. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the timing slot in the fuel injection pump camshaft.3. Disconnect wire (2) from fuel shut off solenoid.
WIRE AND HOUSING
2. Wire. 3. Tachometer drive adapter housing.4. Remove the tachometer drive adapter housing (3).5. Use ratchet (4) and socket (5) to loosen automatic timing advance unit from fuel injection pump camshaft. Back off retaining bolt. The bolt will feel loose, then tighten up again when taper starts to separate from the camshaft.
REMOVING RETAINING BOLT
4. 8H8572 Ratchet. 5. 8S2357 Deep Well Socket.6. Remove the plug from timing hole (7) in the front cover and insert bolt (6). The cover retaining bolt from hole (8) may be used.
INSTALLING BOLT
6. 1D4539 Bolt [5/16 in. - 18 NC, 2.5 in. (63,5 mm) long]. 7. Timing hole. 8. Hole.7. Rotate crankshaft CLOCKWISE (as viewed from front of engine) until bolt (6) threads into the timing gear and is centered in timing hole (7). With timing pin in slot in fuel pump camshaft and the bolt (6) through the front cover and threaded into the timing gear, the fuel injection pump camshaft is timed to the engine.8. Remove the fuel injection pump housing retaining bolts (9).
RETAINING BOLTS
9. Retaining bolts.9. Remove the fuel injection pump housing and governor as a unit.
REMOVING HOUSINGInstall Fuel Injection Pump Housing and Governor
1. Install the fuel injection pump housing and governor as a unit. Install the fuel injection pump housing retaining bolts.2. Install the automatic timing advance unit retaining bolt and tighten retaining bolt to 35 2 lb. ft. (4.8 0.3 mkg).3. To check timing remove the timing pin and the bolt. Rotate the crankshaft two revolutions CLOCKWISE (as viewed from front of engine) and install the timing pin and bolt back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be retimed.4. Remove the bolt (6) from the timing gear and install in hole (8). Install the plug into timing hole (7).5. Remove the timing pin from the timing slot in the fuel injection pump camshaft and install the plug in the timing hole.6. Install the tachometer drive adapter housing. Connect the wire to the fuel shut off solenoid.Disassemble Max-Min Governor
MAX-MIN GOVERNOR DISASSEMBLED
1. Seal. 2. Link. 3. Yoke. 4. Coned disc washer. 5. Washer.Assemble Max-Min Governor
MAX-MIN GOVERNOR
1. Seal. 2. Link. 3. Yoke. 4. Coned disc washer. 5. Washer.Install seal (1) with lip facing toward inside of governor housing.Link (2) must turn freely on yoke (3).Install coned disc washer (4) with concave side toward washer (5). The 1160 Engines, 5.0 in. (127.0 mm) stroke, do not have washer (4).
After disassembly and assembly, use the following initial settings to protect the engine from overspeed.
Disassemble Hydraulic Governor (9L9540 Governor)
HYDRAULIC GOVERNOR DISASSEMBLED
1. Seal. 2. Seal. 3. Weights.Assemble Hydraulic Governor (9L9540 Governor)
HYDRAULIC GOVERNOR
1. Seal. 2. Seal. 3. Weights.Lubricate seal (1) and all adjoining surfaces with clean engine oil (SAE 30).Install seal (2)