101601-4290 ZEXEL 9 400 614 588 BOSCH INJECTION-PUMP ASSEMBLY 9400614588 1016014290 5156004987

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 588 9400614588

ZEXEL 101601-4290 1016014290

ISUZU 5156004987 5156004987

Service parts 101601-4290 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0570

3. GOVERNOR 105931-0160

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS 105612-1560

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101601-4290 as INJECTION-PUMP ASSEMBLY

106675-4320 as _

Cross reference number

BOSCH 9 400 614 588 9400614588

ZEXEL 101601-4290 1016014290

ISUZU 5156004987 5156004987

Zexel num

Bosch num

Firm num

Name

101601-4290

9 400 614 588

5156004987 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * 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 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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive 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 H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 9.9 8.6 11.2

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point A

Rack position R1(10.6+ -0.5)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 52.8 51.8 53.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point B

Rack position 10.5+-0. 5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 54.2 52.6 55.8

Fixing the lever *

Injection quantity adjustment_04

Adjusting point C

Rack position 10.6+-0. 5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 54.3 52.7 55.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position 10.7+-0. 5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 45.8 44.2 47.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position R2(13.1+ -0.5)

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 66.4 61.4 71.4

Fixing the rack *

Timer adjustment

Pump speed r/min 1350+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 2.1 1.6 2.6

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards. (4)Perform governor spring adjustment by setting lever a. (5)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b. (6)After completing final adjustment, set the lever to obtain J. (7)Next, confirm rack position R1 or more is obtained when rotation is stopped. (8)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit). (9)After completing final adjustment, set speed at N1 using lever b. (10)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit). (11)For the excess fuel setting for starting rack position point I set the lever to obtain standard c in step (8) and then set the rack limit.
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T1=10 R1=12mm N1=225r/min
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