106671-6025 ZEXEL 9 400 610 869 BOSCH INJECTION-PUMP ASSEMBLY 9400610869 1066716025 1156030685

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 869 9400610869

ZEXEL 106671-6025 1066716025

ISUZU 1156030685 1156030685

Service parts 106671-6025 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0770

3. GOVERNOR 105923-1814

4. SUPPLY PUMP 105237-4730

5. AUTOM. ADVANCE MECHANIS 105681-1860

6. COUPLING PLATE 105664-0881

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4562

11. Nozzle and Holder 1-15300-356-0

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105041-3071

14. NOZZLE 105025-1110

15. NOZZLE SET

Include in #1:

106671-6025 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 869 9400610869

ZEXEL 106671-6025 1066716025

ISUZU 1156030685 1156030685

Zexel num

Bosch num

Firm num

Name

106671-6025
106671-6026

9 400 610 869

1156030685 ISUZU

INJECTION-PUMP ASSEMBLY
6WA1-TC K 14CA INJECTION PUMP ASSY 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 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 5.2 5.17 5.23

Rack position
Point A R=A

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 -

Rack position 12.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 139 137 141

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6.5+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 15 11.8 18.2

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 139 137 141

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 125.5 119.5 131.5

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Boost compensator adjustment

Pump speed r/min 450 450 450

Rack position R2-2.3

Boost pressure kPa 8.7 7.4 10

Boost pressure mmHg 65 55 75

Boost compensator adjustment_02

Pump speed r/min 450 450 450

Rack position R2(R1-0. 65)

Boost pressure kPa 30.7 30.7 30.7

Boost pressure mmHg 230 230 230

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 950

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
T1=AD86 BCL=2.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=4deg+-5deg b=30.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=0r/min cc=1+-0.3mm
----------
a=18deg+-5deg b=44deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=9deg
----------
a=(100deg)