106671-6751 ZEXEL 9 400 613 441 BOSCH INJECTION-PUMP ASSEMBLY 9400613441 1066716751 1156035002

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 441 9400613441

ZEXEL 106671-6751 1066716751

ISUZU 1156035002 1156035002

Service parts 106671-6751 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6300

3. GOVERNOR 105407-8451

4. SUPPLY PUMP

105237-4421

5. AUTOM. ADVANCE MECHANIS 105681-6100

6. COUPLING PLATE 105664-2011

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8310

11. Nozzle and Holder 1-15300-428-0

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

13. NOZZLE-HOLDER 105041-2082

14. NOZZLE

15. NOZZLE SET 105019-2840

Include in #1:

106671-6751 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 441 9400613441

ZEXEL 106671-6751 1066716751

ISUZU 1156035002 1156035002

Zexel num

Bosch num

Firm num

Name

106671-6751
106671-6752

9 400 613 441

1156035002 ISUZU

INJECTION-PUMP ASSEMBLY
6HK1-T * 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 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 3.4 3.37 3.43

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 10.8

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 109.5 108.5 110.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 131 131

Boost pressure mmHg 980 980

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 13.5 10.3 16.7

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 11++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 100 120

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1.25

Boost pressure kPa 44 40 48

Boost pressure mmHg 330 300 360

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(10.8)

Boost pressure kPa 117 110.3 123.7

Boost pressure mmHg 880 830 930

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1(500)

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min (670)+-2 5

Advance angle deg. -2.5 -3 -2

Remarks
Finish

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)Deliver with positive torque control spring not operating (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Set idle sub-spring
----------
K=8 BCL=1.25+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=8deg+-5deg b=31deg+-3deg c=27deg+-5deg

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
----------
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, assemble then tighten the bolts to remove the heads. (B): Specified torque (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)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(50deg)