101603-8862 ZEXEL 9 400 615 281 BOSCH INJECTION-PUMP ASSEMBLY 9400615281 1016038862 8943909612

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 281 9400615281

ZEXEL 101603-8862 1016038862

ISUZU 8943909612 8943909612

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101482-4480 as _

Cross reference number

BOSCH 9 400 615 281 9400615281

ZEXEL 101603-8862 1016038862

ISUZU 8943909612 8943909612

Zexel num

Bosch num

Firm num

Name

101603-8862

9 400 615 281

8943909612 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(10.9)

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:

WRENCH INSTALLED
1. 8S2243 Wrench. 2. Protective cap. 3. Retaining bushing.c. Install extractor (4).d. Remove retaining bushing (3) and wrench (1).e. Remove the seal and lift fuel injection pump (5) out of the housing. Keep components together and identified as to location.4. Remove rack (7) and rack bumper spring (6).
REMOVING PUMP
4. 8S2244 Extractor. 5. Fuel injection pump.
REMOVING RACK
6. Rack bumper spring. 7. Rack.5. Use magnet (8) to remove lifters (9). Identify lifters (9) and keep them with their respective fuel injection pumps.
REMOVING LIFTERS
8. 8S2293 Magnet. 9. Lifter.6. Remove the camshaft gear assembly retaining bolt (11) and lock. Remove plate assembly (10).
REMOVING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt.7. Remove camshaft gear assembly (12) from camshaft (13).
REMOVING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.
REMOVING BOLTS
14. Lock. 15. Bolts.8. Remove bolts (15) and lock (14).9. Remove camshaft retaining plate (16).
REMOVING RETAINING PLATE
16. Retaining plate.10. Remove camshaft (13).
REMOVING CAMSHAFT
13. Camshaft.11. Use camshaft bearing removal and installation group (17) to remove the camshaft bearings from the fuel injection pump housing.
REMOVING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.Assemble Fuel Injection Pump Housing
1. Use camshaft bearing removal and installation group (17) to install the camshaft bearings in the fuel injection pump housing. The camshaft bearings must be installed with the oil holes in the bearings in line with the oil hole in the housing. The front and rear bearings must be line bored after installation. To align oil holes and line bore the bearings, See Special Instruction (GMG00672).
INSTALLING BEARINGS
17. 8S2241 Camshaft Bearing Removal and Installation Group.2. Put clean engine oil (SAE 30) on the camshaft and install camshaft (13) in the fuel injection pump housing.
INSTALLING CAMSHAFT
13. Camshaft.3. Install the camshaft retaining plate (16).4. Install lock (14) and bolts (15).
INSTALLING RETAINING PLATE
16. Retaining plate.
INSTALLING BOLTS
14. Lock. 15. Bolts.5. Install camshaft gear assembly (12) on camshaft (13).
INSTALLING GEAR ASSEMBLY
12. Gear assembly. 13. Camshaft.6. Install plate assembly (10), retaining bolt (11), and lock.
INSTALLING PLATE ASSEMBLY
10. Plate assembly. 11. Bolt. Be sure to put the spacer on bolt (11).7. Use magnet (8) to install lifters (9). The lifters (9) must be installed in the same location from which they were removed.
INSTALLING LIFTERS
8. 8S2293 Magnet. 9. Lifters.8. Lubricate the rack with clean fuel oil. Install rack (7) with timing pin slot in rack toward front of the housing. Install rack bumper spring (6) so the large diameter of the bumper spring will be against the housing. If new lifters and pumps are to be installed it will be necessary to check and/or adjust the fuel pump timing dimension. See FUEL PUMP TIMING DIMENSION SETTING-OFF ENGINE in TESTING AND ADJUSTING section of the Service Manual.
INSTALLING RACK
6. Rack bumper spring. 7. Rack.9. Remove bolts (19) and rack cover (18).
RACK COVER
18. Rack cover. 19. Bolts.
TIMING PIN INSTALLED
20. Slot in rack. 21. 8S2291 or FT887 Timing Pin.10. The rack must be centered to install the fuel injection pumps. To center the rack, pull the rack toward the governor end of the housing until centering slot (20) in the rack is under the centering pin hole.