Information injection-pump assembly
BOSCH
9 400 612 271
9400612271
ZEXEL
106671-6451
1066716451
ISUZU
1156033341
1156033341
Rating:
Service parts 106671-6451 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-389-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}/22.1{225}
14.
NOZZLE
Include in #1:
106671-6451
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 271
9400612271
ZEXEL
106671-6451
1066716451
ISUZU
1156033341
1156033341
Zexel num
Bosch num
Firm num
Name
9 400 612 271
1156033341 ISUZU
INJECTION-PUMP ASSEMBLY
6HK1-TC * K 14CA PE6P,6PD PE
6HK1-TC * K 14CA PE6P,6PD PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
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.
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.
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
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
----------
----------
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
----------
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
----------
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)
----------
----------
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 installation hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=9deg
----------
a=(50deg)
----------
aa=9deg
----------
a=(50deg)
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 oil step speed calibration increases the oil step speed setting or the oil step speed calibration decreases the oil step speed setting. Refer to the Speed Specification Chart in order to find the oil step speed that is equal to the engine rpm when the engine is running.
Remove the lockwire and the seal from seal screw plug (6). Remove seal screw plug (6) from the access hole for the oil step speed adjusting screw.
Use a small screwdriver to lightly turn the oil step speed adjusting screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw twenty times. The oil step speed adjusting screw will vary the setting of a potentiometer that is inside of the ESS. The oil step speed adjusting screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Connect a voltmeter with the positive lead at terminal (ESS-13) and the negative lead at (ESS-5). Use a 6V-7070 Digital Multimeter or a voltmeter with the same accuracy. Measure the voltage.
For a specific engine rating, find the engine rpm in the column for the oil step speed setting in the Speed Specification Chart. Run the engine at the rpm that is specified in the table.
While the engine is running, look into the hole for the adjustment of the oil step speed. A red indicator lamp should be lighted. A positive voltage should be observed on the multimeter 9 seconds after the indicator lamp is lighted. Turn the oil step speed adjusting screw clockwise until the indicator lamp turns off. The oil step speed setting is above the present rpm of the engine. Slowly turn the oil step speed adjusting screw counterclockwise until the indicator lamp is lighted. After a 9 second delay, a positive voltage should be observed on the multimeter. This position is the correct setting for the oil step speed.
Install seal screw plug (6) in the access hole for the oil step speed adjusting 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 overspeed calibration and the crank terminate speed calibration are also complete.