106671-6442 ZEXEL 9 400 612 502 BOSCH INJECTION-PUMP ASSEMBLY 9400612502 1066716442 1156034161

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 502 9400612502

ZEXEL 106671-6442 1066716442

ISUZU 1156034161 1156034161

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Buy INJECTION-PUMP ASSEMBLY 106671-6442 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-6442 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6240

3. GOVERNOR 105407-7741

4. SUPPLY PUMP 105237-4730

5. AUTOM. ADVANCE MECHANIS 105681-2750

6. COUPLING PLATE 105664-0881

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8201

11. Nozzle and Holder 1-15300-413-0

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.1{225}

13. NOZZLE-HOLDER 105041-4371

14. NOZZLE

15. NOZZLE SET 105019-2730

Include in #1:

106671-6442 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 502 9400612502

ZEXEL 106671-6442 1066716442

ISUZU 1156034161 1156034161

Zexel num

Bosch num

Firm num

Name

106671-6442

9 400 612 502

1156034161 ISUZU

INJECTION-PUMP ASSEMBLY
6WG1-TQA * 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 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 3.9 3.87 3.93

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 A

Rack position 11.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 226 224 228

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 153 153

Boost pressure mmHg 1150 1150

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 15.5 12.3 18.7

Max. variation between cylinders % 0 -13 13

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 11.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 315 305 325

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 R1-0.9

Boost pressure kPa 89.3 85.3 93.3

Boost pressure mmHg 670 640 700

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.3)

Boost pressure kPa 140 140 140

Boost pressure mmHg 1050 1050 1050

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min 650-50

Advance angle deg. -1.25 -1.75 -0.75

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)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Main spring setting
----------
K=8 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=70mm
----------
a=22deg+-5deg b=13deg+-3deg c=19deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position = aa, speed = bb (stamp at delivery) (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=23mm
----------
a=53deg+-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 maximum)
----------
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=10deg
----------
a=(100deg)

Information:

Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The overspeed calibration can increase the overspeed setting or the overspeed calibration can decrease the overspeed setting in order to shut down the engine when the overspeed verification button is pressed. The overspeed setting is correctly made when the engine is running at 75% of the overspeed setting. The engine then shuts down when the overspeed verification button is pressed.Use the following procedure in order to adjust the overspeed setting.
Remove the lockwire and the seal from seal screw plug (4). Remove seal screw plug (4) from the access hole for the overspeed adjustment screw.
Use a small screwdriver to lightly turn the overspeed adjustment screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw 20 times. The overspeed adjustment screw will vary the setting of a potentiometer that is inside of the ESS. The overspeed adjustment screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Run the engine at 75% of the desired overspeed setting rpm. Refer to the Speed Specification Chart.
While the engine is running at 75% of the overspeed setting rpm, press "VERIFY" button (1). While the button is depressed, slowly turn the overspeed adjustment screw in the opposite direction of the "MAX" arrow or the counterclockwise direction until overspeed indicator lamp (3) is lighted. The engine will shut down if the ESS is connected to the fuel shutoff solenoid (FSOS) and the air shutoff solenoid, if equipped.
In order to reset the ESS, press "RESET" button (2). The air shutoff valve must be reset by hand, if equipped.
Slowly turn the overspeed adjustment screw in the clockwise direction for one turn. Repeat Steps 3, 4, and 5. More adjustment may be necessary in order to gain the correct setting. Turn the overspeed adjustment screw in the clockwise direction in order to increase the overspeed setting. Turn the overspeed adjustment screw in the counterclockwise direction in order to decrease the overspeed setting.
When the overspeed setting is correct, install seal screw plug (4) in the access hole for the overspeed adjustment screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the calibration of the crank termination speed and the oil step speed calibration are also complete.