101601-8700 ZEXEL 9 400 614 671 BOSCH INJECTION-PUMP ASSEMBLY 9400614671 1016018700 1156017150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 671 9400614671

ZEXEL 101601-8700 1016018700

ISUZU 1156017150 1156017150

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Service parts 101601-8700 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0850

3. GOVERNOR 105931-1351

4. SUPPLY PUMP 105220-7260

5. AUTOM. ADVANCE MECHANIS 105612-3120

6. COUPLING PLATE 105661-0681

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6051

11. Nozzle and Holder 1-15300-134-0

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE 105015-5720

15. NOZZLE SET

Include in #1:

101601-8700 as INJECTION-PUMP ASSEMBLY

106684-4070 as _

Cross reference number

BOSCH 9 400 614 671 9400614671

ZEXEL 101601-8700 1016018700

ISUZU 1156017150 1156017150

Zexel num

Bosch num

Firm num

Name

101601-8700

9 400 614 671

1156017150 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE INJECTION PUMP ASSY PE6A 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 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

Rack position
Point A R=A

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 10.7

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 52.5 50.9 54.1

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 9.8+-0.5

Pump speed r/min 300 300 300

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(10.7)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 52.5 51.5 53.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 59 55.8 62.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.15

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 58.3 55.1 61.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 15.3+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 85

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1050

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 1.2 0.7 1.7

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=97
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-5deg b=43deg+-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=9deg
----------
a=(60deg)

Information:

1. Remove cylinder head bolts (1) and (2).
When lifting cylinder head, care must be taken to keep cylinder head level to prevent damage to the two cylinder head-to-spacer block dowels.
2. Lift the cylinder head off the spacer block. The approximate weight of the cylinder head is 236 kg (520 lb). The following steps are for the installation of the cylinder head.3. Thoroughly clean cylinder head and spacer block surfaces.4. Position the head gasket and the cylinder head onto the dowels in the spacer block. Lower the cylinder head onto the spacer block.5. Put engine oil on the threads of bolts (1) and (2), then install bolts. Tighten bolts (1) and (2) as follows:
Cylinder Head Tightening Sequencea. Tighten bolts 1 thru 26 in number sequence shown to a torque of 150 15 N m (110 11 lb ft).b. Tighten bolts 1 thru 26 in number sequence shown to a torque of 275 15 N m (200 11 lb ft).c. Retorque bolts 1 thru 26 in number sequence shown to 275 15 N m (200 11 lb ft).d. Tighten bolts 27 thru 33 in number sequence show to a torque of 25 7 N m (18 5 lb ft).End By:a. install valve cover baseb. install (EUI) fuel injectorsc. install rocker arm assemblies and push rodsd. adjust all the valve rocker arm clearances.e. install water outlet manifoldf. install exhaust manifold