106961-6150 ZEXEL 9 400 613 337 BOSCH INJECTION-PUMP ASSEMBLY 9400613337 1069616150 1156013948

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 337 9400613337

ZEXEL 106961-6150 1069616150

ISUZU 1156013948 1156013948

Service parts 106961-6150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106096-9133

3. GOVERNOR 105488-8512

4. SUPPLY PUMP 105237-1940

5. AUTOM. ADVANCE MECHANIS 105687-0691

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7003

11. Nozzle and Holder 1-15300-138-2

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.1{225}

13. NOZZLE-HOLDER 105031-4831

14. NOZZLE

105015-6250

15. NOZZLE SET

Include in #1:

106961-6150 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 337 9400613337

ZEXEL 106961-6150 1069616150

ISUZU 1156013948 1156013948

Zexel num

Bosch num

Firm num

Name

106961-6150
106961-6151

9 400 613 337

1156013948 ISUZU

INJECTION-PUMP ASSEMBLY
12PC1 * K 14CE PE10P 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 134424-2220

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-9-8- 5-2-11-1 0-3-6-7-

Pre-stroke mm 4 3.97 4.03

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 15 14.75 15.25

Difference between angles 2
Cal 1-9 deg. 60 59.75 60.25

Difference between angles 3
Cal 1-8 deg. 75 74.75 75.25

Difference between angles 4
Cal 1-5 deg. 120 119.75 120.25

Difference between angles 5
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 6
Cal 1-11 deg. 180 179.75 180.25

Difference between angles 7
Cal 1-10 deg. 195 194.75 195.25

Difference between angles 8
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 9
Cal 1-6 deg. 255 254.75 255.25

Difference between angles 10
Cal 1-7 deg. 300 299.75 300.25

Difference between angles 11
Cal 1-12 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 89.8 88.3 91.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 105.7 103.7 107.7

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 108 104 112

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_04

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 14.5 13.1 15.9

Max. variation between cylinders % 0 -13 13

Fixing the rack *

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

Injection quantity adjustment_05

Adjusting point F

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 135 135

Fixing the lever *

Remarks
When manual lever is on the boost side

Timer adjustment

Pump speed r/min 1050+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 7.5 7 8

Remarks
Finish

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 with the damper spring not operating. (5)At excess fuel lever operation: not exceeding EXL (6)Excess fuel setting for starting: SXL (7)Supply solenoid operating voltage DC24V and move the solenoid body so that the excess lever reaches the excess position at the solenoid's maximum stroke.
----------
RT=0.8 TH=1.8mm EXL=1.5mm SXL=10.2+-0.1mm
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Speed control lever angle

F:Full speed
----------

----------
a=10deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=40mm
----------
a=10deg+-5deg b=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=60deg+-5deg b=73deg+-5deg

0000001101

N:Normal B:When boosted
----------

----------
a=(5deg) b=(24deg)

Timing setting

(1)Pump vertical direction (2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side) (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(170deg)