101601-7480 ZEXEL 9 400 610 160 BOSCH INJECTION-PUMP ASSEMBLY 9400610160 1016017480 1156009453


 

Information injection-pump assembly

BOSCH 9 400 610 160 9400610160
ZEXEL 101601-7480 1016017480
ISUZU 1156009453 1156009453
101601-7480 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7480 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4211
3. GOVERNOR 105470-1130
4. SUPPLY PUMP 105210-4271
5. AUTOM. ADVANCE MECHANIS 105644-0021
6. COUPLING PLATE 105662-0630
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4850
11. Nozzle and Holder 1-15300-088-1
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105031-3620
14. NOZZLE 105015-4390
15. NOZZLE SET

Include in #1:

101601-7480 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 160 9400610160
ZEXEL 101601-7480 1016017480
ISUZU 1156009453 1156009453


Zexel num
Bosch num
Firm num
Name
101601-7480 
101601-7830 
9 400 610 160 
1156009453  ISUZU
INJECTION-PUMP ASSEMBLY
6QA1 * K 14BF PE6AD PE

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   131424-0220
Overflow valve opening pressure kPa   147 113 181
Overflow valve opening pressure kgf/cm2   1.5 1.15 1.85
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   1-4-2-6- 3-5
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   10.9
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   106.2 104.2 108.2
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   11.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   108.1 107.1 109.1
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   C
Rack position   8.6+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   11.5 9.2 13.8
Max. variation between cylinders %   0 -13 13
Fixing the rack   *
Injection quantity adjustment_04
Adjusting point   D
Rack position   -
Pump speed r/min   150 150 150
Each cylinder's injection qty mm3/st.   140 140
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   500
Advance angle deg.   0.3
Timer adjustment_02
Pump speed r/min   600
Advance angle deg.   0.8 0.1 0.8
Timer adjustment_03
Pump speed r/min   700
Advance angle deg.   0.8 0.3 1.3
Timer adjustment_04
Pump speed r/min   900
Advance angle deg.   2 1.5 2.5
Timer adjustment_05
Pump speed r/min   1150
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7480
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=6.5+-0.5mm SXL=12.1+-0.1mm
----------

0000000901

Test data 101601-7480
F:Full load I:Idle (1)Stopper bolt setting (2)Attach the return spring to the upper hole and adjust.
----------

----------
a=4deg+-5deg b=21deg+-3deg

Stop lever angle

Test data 101601-7480
N:Pump normal S:Stop the pump.
----------

----------
a=35.5deg+-5deg b=71deg+-5deg




Information:


If the vessel cannot continue under its own power, it is recommended that the vessel be towed. The propeller of a vessel being towed will windmill through the water. Propeller rotation causes the propeller shaft to rotate. An extended period of propeller shaft rotation without proper lubrication will damage the marine transmission shaft bearings. If pressurized oil cannot be supplied to the marine transmission shaft bearings during towing, the propeller shaft must be secured to prevent propeller shaft rotation.
Most marine transmissions can be back driven (propeller wind milling with dead engine) under the following conditions, provided that vessel speed does not exceed normal maximum propulsion speed of the vessel. For intermittent back driving, such as:* Sailboat auxiliary (short trips)* Towing purse boats in seining operations1. Start the engine and operate the marine gear in neutral, at normal oil pressure, for a minimum of five minutes. Do this once every 24 hours.2. Maintain the marine transmission oil level the same for back driving as for normal propulsion, or keep level above FULL mark on dipstick.3. Make sure the marine transmission is in neutral while the craft is being towed. For continuous back driving, such as:* Sailboat auxiliary (long trips)* Towing to deliver a boat* Towing home a boat with engine trouble (long trip-more than a day)1. Operate in neutral with oil at normal oil pressure for a minimum of five minutes every 12 hours.2. Fill the marine gear with oil until the oil level touches the input shaft on the engine centerline.3. Make sure the marine transmission is in neutral while the craft is being towed.Securing the Propeller
Reverse wind milling can cause engine damage. The best way to prevent reverse wind milling is to secure the propeller. If possible, lock the propeller shaft to prevent rotation.After the propeller shaft has been secured, have the towing vessel travel at slow speed in order to minimize the wind milling force on the propeller. If the vessel is being towed and the marine transmission is allowed to windmill for long periods, the engine must be started and the marine transmission operated for five minutes every 12 hours to lubricate the propeller shaft bearings.There are several ways of preventing propeller shaft rotation. The correct method depends upon the turning force of the propeller, and the construction of the propeller shaft tunnel. Use the method best suited for the type of installation.Propeller Shaft Wrapping
1. On small vessels, wrap a heavy rope around the propeller shaft. The number of wraps needed will depend upon the mass of the propeller and propeller shaft.2. Secure the rope in the opposite direction of propeller shaft rotation.Securing the Companion Flange
1. Remove one or more bolts from the companion flange coupling. Bolt a chain to the companion flange. Wrap the chain several times around the propeller shaft.2. Secure the loose end of the chain at a right angle to the propeller shaft and in the opposite direction of propeller shaft rotation.

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101601-7480  

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