101603-7721 ZEXEL 9 400 615 208 BOSCH INJECTION-PUMP ASSEMBLY 9400615208 1016037721 8943933422


101603-7721 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 208 9400615208
ZEXEL 101603-7721 1016037721
ISUZU 8943933422 8943933422

Service parts 101603-7721 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4960
3. GOVERNOR 105931-8620
4. SUPPLY PUMP 105210-5110
5. AUTOM. ADVANCE MECHANIS 105643-0620
6. COUPLING PLATE 105661-0840
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-5084
11. Nozzle and Holder 8-94397-483-2
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105048-3862
14. NOZZLE 105017-1090
15. NOZZLE SET

Include in #1:

101603-7721 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 208 9400615208
ZEXEL 101603-7721 1016037721
ISUZU 8943933422 8943933422


Zexel num
Bosch num
Firm num
Name
101603-7721 
9 400 615 208 
8943933422  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.   66.9 65.3 68.5
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   265 265 265
Average injection quantity mm3/st.   9 7.7 10.3
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.   66.9 65.9 67.9
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   78.5 74.5 82.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.3
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   49.7 46.5 52.9
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   99 99 131
Fixing the lever   *
Timer adjustment
Pump speed r/min   1210--
Advance angle deg.   0 0 0
Load   3/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1160
Advance angle deg.   0.3
Load   3/4
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   5.5 5 6
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-7721
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G22
----------

Speed control lever angle

Test data 101603-7721
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=38deg+-3deg

Stop lever angle

Test data 101603-7721
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=62.5mm
----------
a=12.5deg+-5deg b=29deg+-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 101603-7721
(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)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 bb=1deg
----------
a=(150deg)




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