101605-0220 ZEXEL 9 400 612 786 BOSCH INJECTION-PUMP ASSEMBLY 9400612786 1016050220 1156034600

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 786 9400612786

ZEXEL 101605-0220 1016050220

ISUZU 1156034600 1156034600

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Buy INJECTION-PUMP ASSEMBLY 101605-0220 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-0220 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8540

3. GOVERNOR 105419-4930

4. SUPPLY PUMP 105220-7580

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-4520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8280

11. Nozzle and Holder 1-15300-425-0

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/22.1{225}

13. NOZZLE-HOLDER 105041-4410

14. NOZZLE

15. NOZZLE SET 105019-2820

Include in #1:

101605-0220 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-1051 as _

Cross reference number

BOSCH 9 400 612 786 9400612786

ZEXEL 101605-0220 1016050220

ISUZU 1156034600 1156034600

Zexel num

Bosch num

Firm num

Name

101605-0220

9 400 612 786

1156034600 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 K 14BF INJECTION PUMP ASSY 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 127 127 127

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 4 3.95 4.05

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 9.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 53 51.5 54.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 375 375 375

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 10.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 140 150

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=15
----------

Speed control lever angle

F:Full speed I:Idle (1)Speed set at aa (setting at supply) (2)Stopper bolt setting (3)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=19deg+-5deg b=7deg+-5deg c=6deg+-5deg

Stop lever angle

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

----------
a=4.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)

Information:

Install Tooling (E). Tighten Tooling (E) to a torque of 9 1 N m (80 9 lb in).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 6 g02025176
Disconnect harness assemblies (3).
Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
Disconnect hose assembly (6).
Illustration 7 g02029098
Disconnect tube assemblies (9).
Disconnect hose assemblies (10) and (11).
Remove bolts (8).
Illustration 8 g02029093
Disconnect tube assembly (12).
Illustration 9 g02025262
Remove bolts (13) and remove fuel pump (14).Installing the Fuel Injection Pump
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
Illustration 10 g02385860
Service replacement pump
Note: Service replacement pump is shipped pinned with warning tag (Z) installed under pinch bolt (E).
Illustration 11 g02025262
Position fuel pump (14) and install bolts (13).
Illustration 12 g02029093
Connect tube assembly (12).
Illustration 13 g02029098
Install bolts (8).
Connect tube assembly (9) and connect both hose assemblies (10) and (11).
Illustration 14 g02025176Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
Connect harness assemblies (3).
Install a new fuel line. Hand tighten nuts (4) and (7).
Position the clamp assembly and install nut (5). Hand tighten the nut. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
Tighten nut (4) at the fuel rail to a torque of 27 3 N m (239 27 lb in).
Tighten nut (7) to a torque of 27 3 N m (239 27 lb in).
Tighten nut (5) to a torque of 12 3 N m (105 27 lb in).
Illustration 15 g02351995
Remove Tooling (E) and warning tag (Z).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 16 g02351981
Install O-ring seal (2) and plug (1). Tighten the plug to a torque of 9 1 N m (80 9 lb in).
Illustration 17 g02112896
Remove all tooling. Reinstall plug (X) into the timing hole that is located in the flywheel housing.
Connect Caterpillar Electronic Technician (ET). Perform a “Fuel System Functional Test ”and a “Fuel System Verification Test”.