101605-0070 ZEXEL 9 400 615 319 BOSCH INJECTION-PUMP ASSEMBLY 9400615319 1016050070 1156033930

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 319 9400615319

ZEXEL 101605-0070 1016050070

ISUZU 1156033930 1156033930

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101401-4322 as _

Cross reference number

BOSCH 9 400 615 319 9400615319

ZEXEL 101605-0070 1016050070

ISUZU 1156033930 1156033930

Zexel num

Bosch num

Firm num

Name

101605-0070

9 400 615 319

1156033930 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 127 127 127

Overflow valve opening pressure kgf/cm2 1.3 1.3 1.3

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 A

Rack position 9.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67 65.5 68.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.1+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8 6.6 9.4

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 115 125

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
----------
K=6
----------

Speed control lever angle

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

----------
a=4deg+-5deg b=16deg+-5deg

Stop lever angle

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

----------
a=53deg+-5deg b=45deg+-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=10deg
----------
a=(60deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Bend the lock tab and remove bolt (1).
The oil pump idler gear (3) can fall off the pump when the pump is removed. Injury can be the result. To prevent injury, always hold idler gear on the pump when the pump is removed.
2. Bend the two tabs on locks (4) on the left hand side of the engine. Remove the four bolts (2) and (5) and remove the oil pump and suction bell as a unit. Be sure the idler gear (3) is engaged with the crankshaft gear and tabs on locks (4) on bolts (5) are not next to the oil pan gasket surface when bolts (2) and (5) are tightened. Install in reverse order.End By:a. install oil pan
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.
Disassemble Oil Pump
Start By:a. remove oil pump
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove idler gear (2). Remove the bearing from the idler gear with tooling (B).2. Remove suction bell (1) and the bolt and the washer from the oil pump drive gear. 3. Remove the drive gear from the shaft with tooling (A).4. Remove the key from the pump shaft and bolts (3). 5. Remove body (8), two gears (7), the keys and spacer (4).6. Remove two shafts (5) and the gears.7. Remove bolts (6), the cover and the pressure relief valve. 8. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly with tooling (B).Assemble Oil Pump
1. Install the bearings in the scavenge pump body assembly with tooling (B) and a press as follows:a. Put bearings (9) in position on the inside of the scavenge pump body assembly with the chamfer on the bearing toward the outside of the pump body. Install the bearing until it is 1.52 mm (.060 in) below the inside machined surface of the scavenge pump body assembly. Make sure the joints in the bearings are at an angle of 30° 15° from the center line through the bores in the scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores. 2. Install the bearings in oil pump body assembly with tooling (B) and a press as follows.a. Put bearings (10) in position on the inside of the oil pump body assembly with the chamfer on the bearings toward the outside of the pump body. Install the bearings until they are even with the outside of the pump at an angle of 30° 15° from the centerline through the bearing bores and toward the outlet passage of the pump. The outlet passage has a cavity between the bearing bores.3. Check