101601-8651 ZEXEL 9 400 610 019 BOSCH INJECTION-PUMP ASSEMBLY 9400610019 1016018651 1156016793

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 019 9400610019

ZEXEL 101601-8651 1016018651

ISUZU 1156016793 1156016793

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106685-4375 as _

Cross reference number

BOSCH 9 400 610 019 9400610019

ZEXEL 101601-8651 1016018651

ISUZU 1156016793 1156016793

Zexel num

Bosch num

Firm num

Name

101601-8651
101601-8652

9 400 610 019

1156016793 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1-T *

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 3.4 3.35 3.45

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 -

Rack position 10.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 72 70.4 73.6

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 -

Rack position 9.6+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 72 71 73

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. 76.5 73.3 79.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 46.5 43.3 49.7

Fixing the lever *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min (1300)

Advance angle deg. 1 0.5 1.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=B51 RAL=13.5+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

Timing setting

(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=16deg
----------
a=(60deg)

Information:

(1) Oil cooler base bypass valve. Opening pressure ... 155 17 kPa (22.5 2.5 psi)(2) Base assembly. Tighten stud that holds filter assembly (3) to a torque of ... 68 7 N m (50 5 lb ft)(3) Filter assembly.(4) Cover. Tighten to a torque of ... 60 10 N m (44 7 lb ft)(5) Seal. Lubricate seal with lubricant being sealed.
Section A-A. Oil Filter Bypass Valve.The bypass opening pressure differential is 170 kPa (25 psi).(6) Seal.(7) Spring (8M3182): Assembled length ... 63.5 mm (2.50 in)Load at assembled length ... 36.5 N (8.92 lb)Free length after test ... 91.7 mm (3.61 in)Outside diameter ... 20.6 mm (.81 in)(8) Seal.(9) Plunger.
Section B-B. Oil Pump Bypass Valve.(10) Spring (2N6005): Assembled length ... 96.52 mm (3.800 in)Load at assembled length ... 92.52 N (20.817 lb)Operating length (min) ... 45.72 mm (1.800 in)Load at min operating length ... 257.55 N (57.949 lb)Free length after test ... 124.71 mm (4.910 in)Outside diameter ... 21.84 mm (.860 in)(11) Valve.(12) Seal.(13) Seal.
Section C-C. High Pressure Relief Valve.The relief pressure is 696 kPa (101 psi).(14) Spacer.(15) Spring (1A2170): Assembled length ... 21.43 mm (.844 in)Load at assembled length ... 198.03 13.35 N (44.500 3.000 lb)Free length after test ... 31.00 mm (1.220 in)Outside diameter ... 19.60 mm (.772 in)(16) Seal.
Oil Cooler Bypass Valve.(17) Minimum stroke ... 8.4 mm (.33 in)(18) Length of valve fully compressed ... 44.2 1 mm (1.70 .04 in)(19) Length of valve fully extended ... 52.6 1 mm (2.10 .04 in)(B) Position "B".Valve Data: Start to close temperature ... 100 to 102.8° C (212 to 217° F)Position "B" temperature activation ... 111.1° C (232° F)Position "B" bypass opening pressure differential ... 155 17 kPa (22 2 psi)Fail safe activation temperature ... 126.7° C (260° F) Unit will stroke to and remain at position "B" at failsafe activation temperature.