101603-8880 ZEXEL 9 400 610 683 BOSCH INJECTION-PUMP ASSEMBLY 9400610683 1016038880 8943909300

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 683 9400610683

ZEXEL 101603-8880 1016038880

ISUZU 8943909300 8943909300

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Buy INJECTION-PUMP ASSEMBLY 101603-8880 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8880 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6240

3. GOVERNOR 105932-2100

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1140

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4531

11. Nozzle and Holder 8-94390-499-0

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-1000

15. NOZZLE SET

Include in #1:

101401-4252 as _

101401-4253

101603-8880 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 683 9400610683

ZEXEL 101603-8880 1016038880

ISUZU 8943909300 8943909300

Zexel num

Bosch num

Firm num

Name

101603-8880

9 400 610 683

8943909300 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 K 14BF INJECTION PUMP ASSY PE6AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 0.95 1.65

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 4.7 4.65 4.75

Rack position
After adjusting injection quantity. R=A

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 12.1

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 70.9 74.1

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 H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8.5 7.2 9.8

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(12.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 74.5 70.5 78.5

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4.5 4.5 4.5

Remarks
Measure the actual speed, stop

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.
----------
T1=L58
----------

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=10deg+-5deg b=40deg+-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

0000001501 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.1)mm Rb=R1-1.05mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.5+-1cm3/1000st Q2=(42.1)+-1.6cm3/1000st

0000001601 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

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)At rack position = bb
----------
aa=6deg bb=12.1mm
----------
a=(150deg)

Information:

ROCKER ARM SHAFT ASSEMBLY
1. Fuel return line (one each head). 2. Bolts and locks (four each head).4. Remove rocker arm shaft assembly (3). Remove push rods (4).
REMOVING ROCKER ARM SHAFT ASSEMBLY
3. Rocker arm shaft assembly (one each head). 4. Push rods (eight each head).Install Rocker Arm Shaft Assemblies
1. Lubricate the cam followers, push rods, and rocker arm shaft assembly with clean engine oil (SAE 30).2. Install push rods. Position the rocker arm shaft assembly on the cylinder head.3. Install the rocker arm shaft assembly retaining bolts and locks. Tighten bolts to 18 5 lb. ft. (2.5 0.7 mkg) and bend the locks.4. Install the fuel return line.5. Adjust the intake valve clearance to .015 in. (0.38 mm) and the exhaust valve clearance to .025 in. (0.64 mm).6. Install valve cover. Install valve cover retaining bolts and tighten bolts to 120 24 lb. in. (138 28 cm.kg).Disassemble Rocker Arm Shaft Assembly
1. Remove retaining bolts and locks from each end of rocker arm shaft assembly and disassemble the rocker arm shaft assembly.
ROCKER ARM SHAFT ASSEMBLY DISASSEMBLED
1. Rocker arm shaft. 2. Rivet. 3. Washers (eight). 4. Rocker arms (two per cylinder). 5. Adjusting screw. 6. Bracket. 7. Oil supply hole.Assemble Rocker Arm Shaft Assembly
1. The oil holes in shaft (1), arms (4) and bracket (6) must be clean and free of dirt or foreign material.2. Install adjusting screws (5) into rocker arms (4) so they extend .44 in. (11.2 mm) below arm. This will avoid forcing valves into piston crowns when rocker arm assembly is installed on cylinder head.
ROCKER ARM SHAFT ASSEMBLY
1. Rocker arm shaft. 2. Rivet. 3. Washers (eight). 4. Rocker arms (two per cylinder). 5. Adjusting screw. 6. Bracket. 7. Oil supply hole.3. Install arms (4) on shaft with washers (3) positioned as shown.4. Position shaft (1) and arms (4) into bracket (6) so screws (5) are on the same side of bracket (6) as oil supply hole (7). Rivet (2) must be on top when shaft (1) is positioned into bracket (6). Later rocker arm shaft assemblies have machined flats (8). The machined flats must be on top when shaft (1) is positioned into bracket (6).
LATER ROCKER ARM SHAFT ASSEMBLY
1. Rocker arm shaft. 6. Bracket. 8. Machined flats (four per shaft).