106671-6450 ZEXEL 9 400 611 899 BOSCH INJECTION-PUMP ASSEMBLY 9400611899 1066716450 1156033340

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 899 9400611899

ZEXEL 106671-6450 1066716450

ISUZU 1156033340 1156033340

Service parts 106671-6450 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6250

3. GOVERNOR 105407-7750

4. SUPPLY PUMP 105237-4420

5. AUTOM. ADVANCE MECHANIS 105681-6000

6. COUPLING PLATE 105664-2011

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8112

11. Nozzle and Holder 1-15300-389-1

12. Open Pre:MPa(Kqf/cm2) 18.1{185}/22.1{225}

13. NOZZLE-HOLDER 105041-2082

14. NOZZLE

15. NOZZLE SET 105019-2660

Include in #1:

106671-6450 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 899 9400611899

ZEXEL 106671-6450 1066716450

ISUZU 1156033340 1156033340

Zexel num

Bosch num

Firm num

Name

106671-6450
106671-6451

9 400 611 899

1156033340 ISUZU

INJECTION-PUMP ASSEMBLY
6HK1-TC * 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 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 2.9 2.87 2.93

Beginning of injection position
Governor 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 12.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 133.5 132.5 134.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 160 160

Boost pressure mmHg 1200 1200

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 9.5 6.3 12.7

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point E

Rack position 13++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 145 165

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 10.5

Boost pressure kPa 48 44 52

Boost pressure mmHg 360 330 390

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position 11.2

Boost pressure kPa 147 140.3 153.7

Boost pressure mmHg 1100 1050 1150

Timer adjustment

Pump speed r/min 1200++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1200.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0.7 0.7 0.7

Remarks
Measure the actual speed, stop

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)Boost compensator stroke: BCL (5)Main spring setting (6)Set idle sub-spring
----------
K=10 BCL=0.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=70mm
----------
a=3deg+-5deg b=18deg+-5deg c=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa (3)Rack position bb, pump speed cc (seal at delivery)
----------
aa=23mm bb=1-0.5mm cc=0r/min
----------
a=15deg+-5deg b=70deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

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=(50deg)