101603-8592 ZEXEL 9 400 610 665 BOSCH INJECTION-PUMP ASSEMBLY 9400610665 1016038592 8943959192

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 665 9400610665

ZEXEL 101603-8592 1016038592

ISUZU 8943959192 8943959192

Service parts 101603-8592 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6120

3. GOVERNOR 105932-1092

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0860

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6092

11. Nozzle and Holder 8-94395-923-2

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE 105017-1900

15. NOZZLE SET

Include in #1:

101492-0610 as _

101603-8592 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 665 9400610665

ZEXEL 101603-8592 1016038592

ISUZU 8943959192 8943959192

Zexel num

Bosch num

Firm num

Name

101603-8592
101603-8593

9 400 610 665

8943959192 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1TC-S * 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 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.5 3.45 3.55

Rack position
Point A 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 12.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98 96.4 99.6

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 H

Rack position 9.5+-0.5

Pump speed r/min 265 265 265

Average injection quantity mm3/st. 10.5 9.2 11.8

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(12.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98 97 99

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.2

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 102.5 99.3 105.7

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.65

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 62.5 59.3 65.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 105 105 137

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 850 850 850

Rack position R1-1.65

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 850 850 850

Rack position R1(12.4)

Boost pressure kPa 53.3 46.6 60

Boost pressure mmHg 400 350 450

Timer adjustment

Pump speed r/min 1175--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1125

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Load 4/4

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)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost. (4)Boost compensator stroke: BCL
----------
T1=L05 Ra=12+-0.5mm BCL=1.65+-0.1mm
----------

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=11deg+-5deg b=35deg+-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

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=9deg
----------
a=(160deg)