101601-8921 ZEXEL 9 400 614 676 BOSCH INJECTION-PUMP ASSEMBLY 9400614676 1016018921 1156015075

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 676 9400614676

ZEXEL 101601-8921 1016018921

ISUZU 1156015075 1156015075

Service parts 101601-8921 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8831

3. GOVERNOR 105472-1130

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS 105622-1330

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4821

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105031-3611

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101601-8921 as INJECTION-PUMP ASSEMBLY

101609-3730 as _

Cross reference number

BOSCH 9 400 614 676 9400614676

ZEXEL 101601-8921 1016018921

ISUZU 1156015075 1156015075

Zexel num

Bosch num

Firm num

Name

101601-8921

9 400 614 676

1156015075 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * 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 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 A

Rack position 8.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 57.4 55.9 58.9

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.6+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 8.5 7.2 9.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 50 50

Fixing the lever *

Remarks
After startup boost setting

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 1050

Advance angle deg. 1.2 0.7 1.7

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)The torque control spring does not operate. (4)Excess fuel setting for starting: SXL (5)Tamper proof (shaft setting) (at N = N1). (6)Damper spring setting: DL
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RT=1 TH=1.5mm SXL=9.4+0.2mm N1=1450r/min DL=6.1-0.2mm
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0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=21deg+-3deg b=33deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=47.5deg+-5deg b=71deg+-5deg

0000001501 TAMPER PROOF

N:Pump speed (r/min) R:Rack position (mm) 1. After governor adjustment, adjust the shaft as described below and stamp the cap. (1)Turn the load lever stopper bolt determining the full rack position (R = Rf) 1~2 turns counterclockwise. (2)Then, increase the full rack position. (3)Operate the pump at N = Nf and turn the shaft (B) clockwise. (4)Adjust so that full rack is Rf+0.4. (5)Tighten nut (A) to the specified torque. (6)Turn the stopper bolt clockwise the same amount that it was turned counter clockwise in (1). (7)Then, align with the full rack position (R = Rf) and fix. (8)Apply thread lock adhesive to the entire circumference of the cap (C) and tap it down to pressfit and seal it.. (9)Check for air tightness.
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Rf=8.8mm Nf=1450r/min
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Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
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aa=17deg
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a=(90deg)