101432-0160 ZEXEL 9 400 610 080 BOSCH INJECTION-PUMP ASSEMBLY 9400610080 1014320160 5156010272

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 080 9400610080

ZEXEL 101432-0160 1014320160

ISUZU 5156010272 5156010272

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Buy INJECTION-PUMP ASSEMBLY 101432-0160 zexel genuine, new aftermarket engine parts with delivery

Service parts 101432-0160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101043-9190

3. GOVERNOR 105410-5030

4. SUPPLY PUMP 105220-4742

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-6320

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1451

11. Nozzle and Holder 5-15300-039-1

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105081-3141

14. NOZZLE

105000-1650

15. NOZZLE SET

Include in #1:

101432-0160 as INJECTION-PUMP ASSEMBLY

103864-0152 as _

Cross reference number

BOSCH 9 400 610 080 9400610080

ZEXEL 101432-0160 1014320160

ISUZU 5156010272 5156010272

Zexel num

Bosch num

Firm num

Name

101432-0160
101432-0161

9 400 610 080

5156010272 ISUZU

INJECTION-PUMP ASSEMBLY
C240 * K

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

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 2.25 2.2 2.3

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 41 40 42

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 12

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 38 36 40

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

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)At rack cap installation: R1
----------
K=12 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=9deg+-5deg b=23deg+-5deg c=32deg+-3deg

Timing setting

(1)Pump vertical direction (2)Gear mark Z for the No. 4 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(60deg)

Information:

1. Install tooling (A) on the BrakeSaver housing and rotor. Tooling (A) holds the BrakeSaver housing and rotor assembly together at installation. This prevents damage to the rotor rings and seals.2. Install a 3/8" - 16 NC forged eyebolt in the top of the BrakeSaver housing, and fasten a hoist to it.3. Install two 5/8" - 18 guide bolts (9) in the crankshaft as shown. Make sure dowel (8) is in alignment with the dowel hole in the rotor assembly, and put BrakeSaver housing (7) in position in the flywheel housing.4. Install the three bolts that hold the BrakeSaver housing to the flywheel housing. Remove tooling (A) and guide pins (9). 5. Connect the oil line to fitting (5).6. Inspect the O-ring seals for damage, and make replacements if needed. Install O-ring seals (10) and (11). Put clean engine oil on the O-ring seals.7. Install manifold (12) into the BrakeSaver control valve, and install the four bolts that hold the manifold to the BrakeSaver housing. 8. Connect BrakeSaver lubrication oil line (1) to the fitting in the BrakeSaver housing.End By:a. install flywheel (BrakeSaver)Disassemble BrakeSaver
Start By:a. remove BrakeSaver1. Remove tooling (A) from the BrakeSaver housing and rotor. Tooling (A) prevents damage to the rotor seals and rings during removal of the BrakeSaver housing. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Put alignment marks on stator (3) and housing (4) for assembly purposes. Remove bolts (5) and the stator. 4. Turn the stator over, and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip-type seal (8) from the sleeve. 6. Remove O-ring seal (11) and the six smaller O-ring seals from the oil holes on the housing.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over, and remove sleeve assembly (17). Remove the lip-type seal and O-ring seal (16) from the sleeve.Assemble BrakeSaver
1. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install O-ring seal (16) on sleeve (17).3. Install the sleeve in the BrakeSaver housing. Make