106671-6161 ZEXEL 9 400 612 501 BOSCH INJECTION-PUMP ASSEMBLY 9400612501 1066716161 1156031221

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 501 9400612501

ZEXEL 106671-6161 1066716161

ISUZU 1156031221 1156031221

Service parts 106671-6161 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-1110

3. GOVERNOR 105923-2481

4. SUPPLY PUMP 105237-4730

5. AUTOM. ADVANCE MECHANIS 105681-2060

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:

106671-6161 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 501 9400612501

ZEXEL 106671-6161 1066716161

ISUZU 1156031221 1156031221

Zexel num

Bosch num

Firm num

Name

106671-6161
106671-6162

9 400 612 501

1156031221 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 105780-8250

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

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 10.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 115 113 117

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 440 440 440

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(10.9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 115 113 117

Basic *

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.05

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 102 96 108

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.8

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.9)

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

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=AE80 BCL=0.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt setting
----------
aa=32mm
----------
a=4deg+-5deg b=26.5deg+-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

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Lever 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. (2)Select C so that dimension L2 can be obtained. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Set to full boost. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=1000r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3[R1-0.05]mm Rb=- Rc=R3-1mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=- P3=61.6+-0.7kPa(462+-5mmHg) Q1=(102)+-3cm3/1000st Q2=- Q3=(87)cm3/1000st

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=16deg
----------
a=(100deg)