101603-8940 ZEXEL 9 400 610 687 BOSCH INJECTION-PUMP ASSEMBLY 9400610687 1016038940 8943913330

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 687 9400610687

ZEXEL 101603-8940 1016038940

ISUZU 8943913330 8943913330

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Buy INJECTION-PUMP ASSEMBLY 101603-8940 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8940 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6260

3. GOVERNOR 105932-0311

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105672-5250

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder 8-94393-335-1

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101491-0681 as _

101603-8940 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 687 9400610687

ZEXEL 101603-8940 1016038940

ISUZU 8943913330 8943913330

Zexel num

Bosch num

Firm num

Name

101603-8940

9 400 610 687

8943913330 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 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 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=13mm
----------
a=(150deg) b=1deg

Information:

REMOVING CAM FOLLOWERS WITH MAGNET2. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing mark on crankshaft gear is aligned with timing mark on camshaft large gear.3. Remove the plug from timing pin hole in fuel injection pump housing and install timing pin (1).4. Remove the tachometer drive adapter housing.5. On engines equipped with the hydraulic governor; Remove the automatic timing advance unit or the fuel injection pump camshaft drive gear by removing the tachometer drive shaft with a 9S5031 (5/8 in.) Deep Well Socket. Using puller group (2), thread the 9S8528 Bolt Assembly into the fuel injection pump camshaft. Do not force the bolt assembly. It should thread easily. Install the 9S8527 Bolt by threading it into the automatic timing advance unit or the fuel injection pump camshaft drive gear. Then tighten the 9S8527 Bolt with a wrench until the automatic timing advance unit or fuel injection pump camshaft drive gear "pops" loose.On engines equipped with the "Max-Min" governor; Loosen the automatic timing advance unit retaining bolt with a 8S2357 (9/16in.) Deep Well Socket. The bolt will first feel loose, then it will tighten again when the taper drive of the automatic timing advance unit starts to separate from the camshaft.
TIMING PIN AND PULLER INSTALLED
1. FT887 Timing Pin (Fabricated Tool). 2. 9S8520 Puller Group.6. Remove the camshaft thrust pin (3) from the rear of the cylinder block.
REMOVING THRUST PIN
3. Thrust pin.7. Pull the camshaft (4) out of the cylinder block, being careful to not damage the camshaft bearings or journals.
REMOVING CAMSHAFT
4. Camshaft.Install Camshaft
1. Lubricate the camshaft bearing surfaces with clean engine oil (SAE 30).2. Install the camshaft with timing mark on camshaft gear aligned with timing mark on crankshaft gear.3. Install the camshaft thrust pin in rear of cylinder block. Tighten the thrust pin to 35 5 lb. ft. (4.8 0.7 mkg).4. Position the automatic timing advance unit or fuel injection pump drive gear on the fuel injection pump camshaft. Install the tachometer drive shaft. Engines equipped with the hydraulic governor; Tighten retaining bolt to 32 2 lb. ft. (4.4 0.3 mkg). Engines equipped with the "Max-Min" governor; Tighten retaining bolt to 35 2 lb. ft. (4.8 0.3 mkg).5. Remove timing pin from fuel injection pump housing and install plug in timing pin hole.6. Install the cam followers in the same location from which they were removed. Always use new cam followers with a new camshaft. Be sure to put clean engine oil on the cam followers and camshaft lobes before installing the cam followers.