101603-7602 ZEXEL 9 400 619 723 BOSCH INJECTION-PUMP ASSEMBLY 9400619723 1016037602 8943969282


101603-7602 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 723 9400619723
ZEXEL 101603-7602 1016037602
ISUZU 8943969282 8943969282

Service parts 101603-7602 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4960
3. GOVERNOR 105931-7992
4. SUPPLY PUMP 105210-5110
5. AUTOM. ADVANCE MECHANIS 105643-0720
6. COUPLING PLATE 105661-0781
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5081
11. Nozzle and Holder 8-94397-483-1
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3862
14. NOZZLE 105017-1090
15. NOZZLE SET

Include in #1:

101603-7602 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 723 9400619723
ZEXEL 101603-7602 1016037602
ISUZU 8943969282 8943969282


Zexel num
Bosch num
Firm num
Name
101603-7602 
101603-7603 
9 400 619 723 
8943969282  ISUZU
INJECTION-PUMP ASSEMBLY
6HE1-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   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   4.2 4.15 4.25
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   11.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69 67.4 70.6
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   9.8+-0.5
Pump speed r/min   265 265 265
Average injection quantity mm3/st.   18.2 16.9 19.5
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(11.1)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   69 68 70
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   103 103 135
Fixing the lever   *
Timer adjustment
Pump speed r/min   (1220)
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   1.3 0.8 1.8
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   5.5 5 6
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7602
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1
----------
T1=G16
----------

Speed control lever angle

Test data 101603-7602
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=28mm
----------
a=12.5deg+-5deg b=(45deg)+-3deg

Stop lever angle

Test data 101603-7602
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-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=131153-4520 ST=A724 L1=1mm L2=4.2+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

Test data 101603-7602
(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)- (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Pointer stamping (9)Timing device stamping (10)Timing device (11)Move b deg and stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=11deg
----------
a=(150deg) b=1deg




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