![101603-8751 INJECTION-PUMP ASSEMBLY](http://fuel-inject.com/static/text/zx/10/1016038751.png)
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Information injection-pump assembly
BOSCH
9 400 610 672
9400610672
ZEXEL
101603-8751
1016038751
ISUZU
8943959211
8943959211
Service parts 101603-8751 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94395-923-2
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 672
9400610672
ZEXEL
101603-8751
1016038751
ISUZU
8943959211
8943959211
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.5
3.45
3.55
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.4
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98
96.4
99.6
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
9.5+-0.5
Pump speed
r/min
265
265
265
Average injection quantity
mm3/st.
10.5
9.2
11.8
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(12.4)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98
97
99
Basic
*
Fixing the lever
*
Boost pressure
kPa
66.7
66.7
Boost pressure
mmHg
500
500
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
102.5
99.3
105.7
Fixing the lever
*
Boost pressure
kPa
66.7
66.7
Boost pressure
mmHg
500
500
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-1.65
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
62.5
59.3
65.7
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
105
105
137
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
850
850
850
Rack position
R1-1.65
Boost pressure
kPa
12
10.7
13.3
Boost pressure
mmHg
90
80
100
Boost compensator adjustment_02
Pump speed
r/min
850
850
850
Rack position
R1(12.4)
Boost pressure
kPa
53.3
46.6
60
Boost pressure
mmHg
400
350
450
Timer adjustment
Pump speed
r/min
1175--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1125
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
![Test data 101603-8751](https://fuel-inject.com/fuel.zw/00003/00003802.png)
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
(4)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost.
----------
T1=L05 BCL=1.65+-0.1mm Ra=12+-0.5mm
----------
----------
T1=L05 BCL=1.65+-0.1mm Ra=12+-0.5mm
----------
Speed control lever angle
![Test data 101603-8751](https://fuel-inject.com/fuel.zw/00003/00003239.png)
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=11deg+-5deg b=35deg+-3deg
Stop lever angle
![Test data 101603-8751](https://fuel-inject.com/fuel.zw/00002/00002384.png)
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
Timing setting
![Test data 101603-8751](https://fuel-inject.com/fuel.zw/00008/00008016.png)
(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=11deg
----------
a=(160deg)
----------
aa=11deg
----------
a=(160deg)