101602-8890 ZEXEL 9 400 611 180 BOSCH INJECTION-PUMP ASSEMBLY 9400611180 1016028890 1156033440

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 180 9400611180

ZEXEL 101602-8890 1016028890

ISUZU 1156033440 1156033440

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Service parts 101602-8890 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6700

3. GOVERNOR 105411-1790

4. SUPPLY PUMP 105220-6240

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-1200

7. COUPLING PLATE 156643-1320

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4170

11. Nozzle and Holder 1-15300-331-0

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105025-0290

15. NOZZLE SET

Include in #1:

101602-8890 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1774 as _

Cross reference number

BOSCH 9 400 611 180 9400611180

ZEXEL 101602-8890 1016028890

ISUZU 1156033440 1156033440

Zexel num

Bosch num

Firm num

Name

101602-8890

9 400 611 180

1156033440 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-T * 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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 10.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 93.5 92 95

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

Injection quantity adjustment_02

Adjusting point C

Rack position 7.3+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 11 9.7 12.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.55

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.7)

Boost pressure kPa 20 14.7 25.3

Boost pressure mmHg 150 110 190

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
----------
K=13 BCL=0.55+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(4deg)+-5deg b=(18deg)+-5deg

Stop lever angle

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

----------
a=12deg+-5deg b=46deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(60deg)

Information:

Image1.1.1
5. Attach a hose to the other end of the fuel rail and hold the free end of the hose in a cup/bucket of water. Hose shown is a JIC 37o ?6 hose. Refer to Illustration 1.2.1
Image1.2.1
6. Pressurize the cooling system with compressed air and regulate pressure between 5-15 psi.
Do Not Exceed 15 psi or Cooling System Damage Can Result.
7. Submerse the hose in a cup/bucket of water.
8. Monitor for 10 minutes and check for a steady rate of air bubbles coming out of the hose that is submersed in the cup/bucket of water.
9. If steady stream of air is present, replace the cylinder head, coolant regulators, and both 030-7937 port connectors. Depending on the application, you will need to replace some cooling system seals. (List of seals by application to be included)
10. Once the cylinder heads have been replaced pressure test the head again using the same procedure. Once this has been completed the cooling system should be flushed using instructions listed below.
Cleaning the Cooling System
1. Drain all of the coolant form cooling system.
2. Fill the cooling system with clean water.
3. Start engine and run it until the thermostat opens.
4. Add two cups of non-foaming liquid automatic dish washer soap.
Note: Do not use plain dish soap. Aeration of the cooling system and resultant damage could occur.
5. After the soap has bee added run engine for approximately twenty minutes. Check to see if the fuel is breaking up.
6. If the fuel is still not breaking up than add two more cups of soap and run for 10 minutes. Drain mixture from cooling system.
7. Fill cooling system with clean water and check surface for fuel. If fuel is present, repeat steps 3 through 7. When water is clear, drain and rinse the cooling system one more time. Then add coolant and conditioner.