101603-8880 ZEXEL 9 400 610 683 BOSCH INJECTION-PUMP ASSEMBLY 9400610683 1016038880 8943909300


101603-8880 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 610 683 9400610683
ZEXEL 101603-8880 1016038880
ISUZU 8943909300 8943909300

Service parts 101603-8880 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6240
3. GOVERNOR 105932-2100
4. SUPPLY PUMP 105210-6080
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 8-94390-499-0
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105030-4700
14. NOZZLE 105025-1000
15. NOZZLE SET

Include in #1:

101603-8880 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 683 9400610683
ZEXEL 101603-8880 1016038880
ISUZU 8943909300 8943909300


Zexel num
Bosch num
Firm num
Name
101603-8880 
9 400 610 683 
8943909300  ISUZU
INJECTION-PUMP ASSEMBLY
6HH1 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 0.95 1.65
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   12.1
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   72.5 70.9 74.1
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   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(12.1)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   72.5 71.5 73.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   74.5 70.5 78.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   -
Advance angle deg.   0 0 0
Remarks
Measure speed (beginning of operation).
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   4.5 4.5 4.5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101603-8880
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=L58
----------

Speed control lever angle

Test data 101603-8880
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=10deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101603-8880
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

0000001501 ACS

Test data 101603-8880
(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=850r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.1)mm Rb=R1-1.05mm Pa=89.8+-2.7kPa(674+-20mmHg) Pb=70.1+-0.7kPa(526+-5mmHg) Q1=72.5+-1cm3/1000st Q2=(42.1)+-1.6cm3/1000st

0000001601 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

Test data 101603-8880
(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=12.1mm
----------
a=(150deg)




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