101603-8950 ZEXEL 9 400 610 688 BOSCH INJECTION-PUMP ASSEMBLY 9400610688 1016038950 8943913340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 688 9400610688

ZEXEL 101603-8950 1016038950

ISUZU 8943913340 8943913340

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Buy INJECTION-PUMP ASSEMBLY 101603-8950 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-8950 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4960

3. GOVERNOR 105932-1150

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1030

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:

101491-0682 as _

101603-8950 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 688 9400610688

ZEXEL 101603-8950 1016038950

ISUZU 8943913340 8943913340

Zexel num

Bosch num

Firm num

Name

101603-8950

9 400 610 688

8943913340 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-N 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 4.2 4.15 4.25

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 11.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77 75.4 78.6

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(11.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77 76 78

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.4

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 77 73 81

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. 66.5 63.3 69.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 127

Fixing the lever *

Timer adjustment

Pump speed r/min (1130)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 5.5 5 6

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=K51
----------

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=12deg+-5deg b=35.5deg+-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=131153-4520 ST=A724 L1=1mm L2=4.2+-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=5deg bb=11.4mm
----------
a=(150deg) b=1deg

Information:

REMOVING CAM FOLLOWERS WITH MAGNET2. Remove the plug from the timing pin hole in the fuel injection pump housing and install timing pin (2).
TIMING PIN INSTALLED
1. FT887 Timing Pin (Fabricated Tool).3. Rotate the crankshaft CLOCKWISE (as viewed from front of engine) until the timing pin drops into the slot in the fuel injection pump camshaft.
PUMP DRIVE GEAR
2. Bolts (three). 3. Tachometer drive assembly. 4. Drive gear.4. Remove bolts (2) and tachometer drive assembly (3) from the fuel injection pump camshaft.5. Remove the fuel injection pump drive gear (4) from the fuel injection pump camshaft.6. Remove the camshaft thrust pin (5) from the rear of the cylinder block.
REMOVING THRUST PIN
5. Thrust pin.7. Pull the camshaft (6) out of the cylinder block, being careful to not damage the camshaft bearings or journals.
REMOVING CAMSHAFT
6. Camshaft.Install Camshaft
1. Lubricate the camshaft bearing surfaces with clean engine oil (SAE 30).2. Install the camshaft aligning timing mark on camshaft gear with timing mark on crankshaft gear.3. Install camshaft thrust pin (5) in rear of cylinder block. Tighten thrust pin to 35 5 lb. ft. (4.8 0.7 mkg).
TIMING MARKS4. Put timing plate (7) on the engine and thread bolt (8) into the timing gear. If bolt (8) will not thread into the timing gear, rotate the crankshaft CLOCKWISE (as viewed from front of engine) until bolt (8) threads into the timing gear.
TIMING PLATE INSTALLED
4. Gear. 7. 5P950 Timing Plate. 8. Bolt.
GEAR INSTALLED
4. Drive gear.5. Install drive gear (4) on the fuel injection pump camshaft with the holes in the position shown and the part number facing out. To be able to advance the timing adjustment without removing the front cover, position gear (4) in the direction of the arrow so the bolt holes in the fuel injection pump camshaft are off center as shown. The bolts must thread freely into the holes in the fuel injection pump camshaft.6. Install the tachometer drive assembly (3) and tighten it finger tight.7. Install bolts (2) and tighten the bolts to 32 5 lb. ft. (4.4 0.7 mkg). Tighten the tachometer drive assembly to 50 10 lb. ft. (6.9 1.4 mkg).8. Remove bolt (8) and remove the timing plate (7) from the engine.
TACHOMETER DRIVE ASSEMBLY INSTALLED
2. Bolts (three). 3. Tachometer drive assembly. 4. Pump drive gear.9. Remove timing pin (1) from fuel injection pump housing and install the plug in the timing pin hole.10. Install the cam followers in the same location from which they were removed. Always use the new cam followers with a new camshaft. Be sure to put engine oil on the cam followers and camshaft lobes before installing the cam followers.