106671-1815 ZEXEL 9 400 611 716 BOSCH INJECTION-PUMP ASSEMBLY 9400611716 1066711815 1156028185

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 716 9400611716

ZEXEL 106671-1815 1066711815

ISUZU 1156028185 1156028185

Service parts 106671-1815 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7701

3. GOVERNOR 105489-3893

4. SUPPLY PUMP 105237-4440

5. AUTOM. ADVANCE MECHANIS 105691-3633

6. COUPLING PLATE 105662-1301

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7442

11. Nozzle and Holder 1-15300-351-0

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/23.5{240}

13. NOZZLE-HOLDER 105030-3462

14. NOZZLE 105015-9190

15. NOZZLE SET

Include in #1:

106671-1815 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 716 9400611716

ZEXEL 106671-1815 1066711815

ISUZU 1156028185 1156028185

Zexel num

Bosch num

Firm num

Name

106671-1815
106671-1816

9 400 611 716

1156028185 ISUZU

INJECTION-PUMP ASSEMBLY
6WA1-TCN * K 14CA PE6P,6PD 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 8-3-600

Overflow valve 134424-4320

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 3.8 3.77 3.83

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 172.5 170.5 174.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 34 34

Boost pressure mmHg 255 255

Injection quantity adjustment_02

Adjusting point B

Rack position 10.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 166.5 160.5 172.5

Fixing the lever *

Boost pressure kPa 34 34

Boost pressure mmHg 255 255

Injection quantity adjustment_03

Adjusting point C

Rack position 5.2+-0.5

Pump speed r/min 230 230 230

Average injection quantity mm3/st. 11.5 8.3 14.7

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 160 160

Fixing the lever *

Boost pressure kPa 34 34

Boost pressure mmHg 255 255

Remarks
After startup boost setting

Injection quantity adjustment_05

Adjusting point E

Rack position 8.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 126.5 123.5 129.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 8.8

Boost pressure kPa 7.3 7.3 8.6

Boost pressure mmHg 55 55 65

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.6

Boost pressure kPa 20.7 20.7 20.7

Boost pressure mmHg 155 155 155

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Deliver without the torque control spring operating. (5)Excess fuel setting for starting: SXL (N = N1) (6)Boost compensator stroke: BCL (7)Damper spring setting
----------
RT=1 TH=3mm SXL=11.5+-0.1mm N1=350r/min BCL=1.8+-0.1mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
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L=1-0.2mm N2=800r/min C2=(8)deg t1=1.7--sec. t2=1.7--sec.
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N1=950++r/min P1=0 kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
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a=3deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=33mm
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a=15deg+-5deg b=32.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=37deg+-5deg b=73deg+-5deg

0000001101

N:Normal B:When boosted
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a=3deg+-5deg b=16.5deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
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N1=700r/min Ra=10.6mm
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0000001601 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
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L=0.8~1mm
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