101603-8671 ZEXEL 9 400 610 671 BOSCH INJECTION-PUMP ASSEMBLY 9400610671 1016038671 8943959681

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 671 9400610671

ZEXEL 101603-8671 1016038671

ISUZU 8943959681 8943959681

Service parts 101603-8671 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6330

3. GOVERNOR 105932-1270

4. SUPPLY PUMP 105210-6090

5. AUTOM. ADVANCE MECHANIS 105672-5290

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4292

11. Nozzle and Holder 8-94395-498-2

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

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0580

15. NOZZLE SET

Include in #1:

101603-8671 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5491 as _

Cross reference number

BOSCH 9 400 610 671 9400610671

ZEXEL 101603-8671 1016038671

ISUZU 8943959681 8943959681

Zexel num

Bosch num

Firm num

Name

101603-8671
101603-8672

9 400 610 671

8943959681 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.95 4.05

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 11.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 89.9 93.1

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 Z

Rack position 9.6+-0.5

Pump speed r/min 240 240 240

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 *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 91.5 90.5 92.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.95

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 100.5 96.5 104.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.6

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 98.5 94.5 102.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 130 130 138

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 0/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 0/4

Timer adjustment_03

Pump speed r/min (900)

Advance angle deg. 0 0 0

Load 4/4

Remarks
Start

Timer adjustment_04

Pump speed r/min 1425

Advance angle deg. 5.5 5 6

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)RACK LIMIT
----------
T1=K97
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=13deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-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=7deg
----------
a=(150deg)