101603-8960 ZEXEL 9 400 610 689 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 610 689 9400610689
ZEXEL 101603-8960 1016038960
ISUZU 1156032360 1156032360

Service parts 101603-8960 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3880
3. GOVERNOR 105921-9240
4. SUPPLY PUMP 105210-5100
5. AUTOM. ADVANCE MECHANIS 105643-0650
6. COUPLING PLATE 105662-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6301
11. Nozzle and Holder 1-15300-263-1
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105030-4351
14. NOZZLE 105015-8640
15. NOZZLE SET

Include in #1:

101603-8960 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 689 9400610689
ZEXEL 101603-8960 1016038960
ISUZU 1156032360 1156032360


Zexel num Bosch num Firm num Firm Name
101603-8960  9 400 610 689  1156032360  ISUZU INJECTION-PUMP ASSEMBLY
6SD1 K 14BF INJECTION PUMP ASSY PE6AD PE

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   L
Left


Injection timing adjustment
Direction of rotation (viewed from drive side)   L
Left
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


Injection quantity adjustment
Adjusting point   -
Rack position   11.9
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   89.8 88.2 91.4
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   290 290 290
Average injection quantity mm3/st.   11.2 9.2 13.2
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(11.9)
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   89.8 88.8 90.8
Basic   *
Fixing the lever   *


Injection quantity adjustment_04
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   88 88 93
Fixing the lever   *
Rack limit   *


Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks  
Start


Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5


Timer adjustment_03
Pump speed r/min   1250
Advance angle deg.   4 3.5 4.5
Remarks  
Finish

Test data Ex:



Governor adjustment

Test data 101603-8960 N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K80
----------



Speed control lever angle

Test data 101603-8960 F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35.5mm
----------
a=18deg+-5deg b=36deg+-3deg



Stop lever angle

Test data 101603-8960 N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=40deg+-5deg



0000001501 TAMPER PROOF

Test data 101603-8960 1. Set the full load. (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to R1. (2)Set using the screw (A) so that the rack position is as shown above and tighten the locknut. (3)Again set in the correct rack position using the load lever.
----------
R1=0.4mm
----------



Timing setting

Test data 101603-8960 (1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(40deg)





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Group cross 101603-8960 ZEXEL

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101603-8910  9 400 610 685  8943913350  INJECTION-PUMP ASSEMBLY
6HH1-N
101603-8920  9 400 615 283  8943913360  INJECTION-PUMP ASSEMBLY
6HH1-S
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6HE1-TC
101603-8940  9 400 610 687  8943913330  INJECTION-PUMP ASSEMBLY
6HH1-S
101603-8950  9 400 610 688  8943913340  INJECTION-PUMP ASSEMBLY
6HH1-N
101603-8960  9 400 610 689  1156032360  INJECTION-PUMP ASSEMBLY
6SD1
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101603-8980  9 400 612 945  1156032720  INJECTION-PUMP ASSEMBLY
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101603-8990 
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101603-8991 
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6HL1-S
101603-8992 
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6HL1-S
101603-8993 
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9 400 611 700  8943906047  INJECTION-PUMP ASSEMBLY
6HL1-S
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