101603-8920 ZEXEL 9 400 615 283 BOSCH INJECTION-PUMP ASSEMBLY 9400615283 1016038920 8943913360

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 283 9400615283

ZEXEL 101603-8920 1016038920

ISUZU 8943913360 8943913360

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101491-0670 as _

Cross reference number

BOSCH 9 400 615 283 9400615283

ZEXEL 101603-8920 1016038920

ISUZU 8943913360 8943913360

Zexel num

Bosch num

Firm num

Name

101603-8920

9 400 615 283

8943913360 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S 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 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 4.7 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 13

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 84.9 88.1

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 -

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(13)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 85.5 87.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 95.5 92.3 98.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 77.5 74.3 80.7

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 5/5

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.
----------
T1=K09
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
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 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 (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Timing device stamping (9)Pointer stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg) b=1deg

Information:

TIMING PIN AND PULLER INSTALLED (Typical Example)
1. FT887 Timing Pin. (Fabricated Tool.) 2. 9S8520 Puller Group.5. Install the 1P2320 Puller and remove the camshaft small outer gear.
PULLING SMALL OUTER GEAR6. Remove the spacer immediately behind the gear.7. Install the 1P2321 Puller and remove the camshaft large inner gear.
PULLING LARGE INNER GEARInstall Camshaft Gears
1. Heat both gears to a maximum temperature of 600° F (315° C) before installing on camshaft.2. Align keyway of large inner gear with key in camshaft. Install large inner gear on camshaft with timing mark on gear aligned with timing mark on crankshaft gear.
TIMING MARKS3. Install the spacer and small outer gear on the camshaft.
Do not drive gears onto camshaft. Serious damage can result to camshaft or camshaft thrust pin.
4. Position the automatic timing advance unit on the fuel injection pump camshaft.5. Install the tachometer drive adapter shaft and tighten shaft retaining nut to 32 2 lb. ft. (4.4 0.3 mkg).6. Remove timing pin from fuel injection pump housing and install the plug.