101603-8662 ZEXEL 9 400 613 140 BOSCH INJECTION-PUMP ASSEMBLY 9400613140 1016038662 8943959803


101603-8662 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 613 140 9400613140
ZEXEL 101603-8662 1016038662
ISUZU 8943959803 8943959803

Service parts 101603-8662 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6310
3. GOVERNOR 105932-1141
4. SUPPLY PUMP 105210-6090
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
12. Open Pre:MPa(Kqf/cm2) 18.1
13. NOZZLE-HOLDER 105030-4700
14. NOZZLE 105025-1000
15. NOZZLE SET

Include in #1:

101603-8662 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 140 9400613140
ZEXEL 101603-8662 1016038662
ISUZU 8943959803 8943959803


Zexel num
Bosch num
Firm num
Name
101603-8662 
101603-8663 
9 400 613 140 
8943959803  ISUZU
INJECTION-PUMP ASSEMBLY
6HH1-S * K 14BF 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   12.6
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   82 80.4 83.6
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   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(12.6)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   82 81 83
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1
Pump speed r/min   1425 1425 1425
Average injection quantity mm3/st.   88.5 85.3 91.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.2
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   72.5 69.3 75.7
Fixing the lever   *
Timer adjustment
Pump speed r/min   1300--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-8662
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=K49
----------

Speed control lever angle

Test data 101603-8662
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=14deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101603-8662
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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%
----------

0000001601 AIR CYLINDER

Test data 101603-8662
1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

Timing setting

Test data 101603-8662
(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=12.6mm
----------
a=(150deg)




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