101605-0020 ZEXEL 9 400 612 418 BOSCH INJECTION-PUMP ASSEMBLY 9400612418 1016050020 1156033830

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 418 9400612418

ZEXEL 101605-0020 1016050020

ISUZU 1156033830 1156033830

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Buy INJECTION-PUMP ASSEMBLY 101605-0020 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-0020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6460

3. GOVERNOR 105419-4290

4. SUPPLY PUMP 105220-6300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE 156635-1820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6682

11. Nozzle and Holder 1-15300-291-2

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

13. NOZZLE-HOLDER 105030-4361

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101491-0721 as _

101605-0020 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 418 9400612418

ZEXEL 101605-0020 1016050020

ISUZU 1156033830 1156033830

Zexel num

Bosch num

Firm num

Name

101605-0020

9 400 612 418

1156033830 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 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 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 8.7

Pump speed r/min 975 975 975

Average injection quantity mm3/st. 59.5 58 61

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position 9.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 60 70

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=17 N1=975r/min N2=500r/min
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Speed control lever angle

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

----------
a=14deg+-5deg b=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

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

Timing setting

(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(15deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove coolant from the engine.2. Loosen two hose clamps (3) and slide hose from tube assembly (2).3. Disconnect tube assembly (1) at the aftercooler cover.4. Remove four bolts holding the tube assembly to the aftercooler housing. Remove tube assembly (2). 5. Remove O-ring seal (4). 6. Remove adapter (5) and the gasket. An O-ring seal on each end of the aftercooler core holds the adapters (5) and (13) in position. 7. Loosen hose clamps (6) and slide hose on the breather tubes. Remove bolt (8) and breather tube (7). 8. Disconnect hose assembly (9).9. Loosen hose clamps (11) and slide the hose from tube assembly (10).10. Remove four bolts fastening the tube assembly to the aftercooler cover. Remove tube assembly (10). 11. Remove O-ring seal (12). 12. Remove adapter (13) and the gasket. 13. Remove the four bolts (14). 14. Remove bolts (17), cover (18) and the gasket. Remove pipe (16). 15. Remove aftercooler core assembly (20) and the gasket. Remove "O'-ring seals (19) from each end of the core. 16. Remove two bolts (21) on the inside of the aftercooler housing. Make a note of the location of bolt spacers before removal. 17. Remove bolts and spacers (23), housing (22) and the gasket. The following steps are to install the jacketwater aftercooler. Inspect all O-ring seals and gaskets and make replacements if necessary. Put a thin layer of clean engine oil on all O-ring seals and in the bores of each adapter.18. Put aftercooler housing gaskets in position on the cylinder head and install aftercooler housing (22). Make a note of the location of two bolts and spacers (23) from the remove story Step 17.19. Install aftercooler core gasket (20).20. Install the O-ring seals (19) on each end of the aftercooler core (20).21. Put the aftercooler core (20) in position in the housing. Put the gasket in place on the core assembly.22. Install turbocharger pipe and the aftercooler cover (18).23. Install four bolts to fasten flange (15) to cover.24. Install gasket and adapter (13). Install breather tube on breather assembly and install the bolt to fasten the breather tube clip to the engine oil cooler.25. Install O-ring seal (12).26. Install tube assembly (10). Slide hose in position and tighten hose clamps.27. Connect hose assembly (9) to tube assembly (10).28. Install gasket and adapter (5).29. Install O-ring seal (4) on tube assembly (2).30. Put tube assembly (2) in position on housing. Make sure tube assembly clip is in place and install the bolts.31. Slide hose in position and tighten two clamps (3).32. Connect tube assembly (1).33. Fill the radiator to the correct level with coolant.
Perform Scheduled Oil Sampling after performing service work to check for coolant leakage and contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.