Information injection-pump assembly
BOSCH
9 400 613 441
9400613441
ZEXEL
106671-6751
1066716751
ISUZU
1156035002
1156035002
Rating:
Service parts 106671-6751 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-428-0
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)22.1(225)
14.
NOZZLE
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
9 400 613 441
1156035002 ISUZU
INJECTION-PUMP ASSEMBLY
6HK1-T * K 14CA PE6P,6PD PE
6HK1-T * 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
3.4
3.37
3.43
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
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.
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
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
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
----------
----------
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
----------
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
----------
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)
----------
----------
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)
----------
aa=12deg
----------
a=(50deg)
Information:
API Degrees - Temperature Correction Chart for Diesel Fuel
Record the corrected API gravity from this chart.Table of Horsepower Correction Factors
Table 2
Corrected API
Gravity at 60° F Precombustion
Chamber Engines Direct Injection Engines (Use the correct full load RPM)
1800 2000 2200 2400 2600 2800 3000 3200
32.0
32.5
33.0
33.5
34.0 .984
.987
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995
34.5
35.0
35.5
36.0
36.5 .997
1.000
1.003
1.005
1.008 .998
1.000
1.003
1.007
1.013 .998
1.000
1.003
1.007
1.010 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012
37.0
37.5
38.0
38.5
39.0 1.011
1.014
1.017
1.020
1.023 1.014
1.018
1.022
1.025
1.029 1.014
1.018
1.022
1.026
1.030 1.014
1.018
1.022
1.026
1.030 1.015
1.019
1.022
1.026
1.030 1.015
1.019
1.023
1.027
1.031 1.016
1.020
1.024
1.028
1.032 1.016
1.020
1.024
1.028
1.033 1.016
1.021
1.025
1.029
1.034
39.5
40.0
40.5
41.0
41.5 1.027
1.030
1.034
1.038
1.043 1.034
1.038
1.043
1.048
1.053 1.034
1.038
1.043
1.048
1.054 1.034
1.039
1.044
1.049
1.055 1.035
1.040
1.045
1.050
1.056 1.036
1.040
1.045
1.051
1.056 1.036
1.041
1.046
1.051
1.057 1.037
1.042
1.047
1.053
1.059 1.039
1.045
1.047
1.057
1.064
42.0
42.5
43.0
43.5
44.0 1.047
1.053
1.060
1.067
1.076 1.059
1.066
1.073
1.082
1.095 1.060
1.067
1.074
1.084
1.096 1.061
1.068
1.076
1.085
1.098 1.062
1.069
1.077
1.086
1.099 1.063
1.070
1.078
1.087
1.100 1.064
1.071
1.079
1.088
1.102 1.066
1.072
1.081
1.091
1.105 1.072
1.080
1.089
1.099
1.115 Use the above chart to find the horsepower correction factor.Calculating the Corrected Horsepower
Determine the rated full load horsepower from the Rack Setting Information Book.
Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the corrected horsepower.Example:1674 - Truck Engine Serial No. 94B2551Rated Horsepower: 270 HorsepowerCalculations:
Table 3
1. Measured API gravity: 40.4' API at 50' (round to 40' API)
2. Corrected API gravity (see chart): 41' API at 60'F
3. Hpr correction factor (see chart): 1.038
4. Corrected Hp = Rated Hpr = 270 = 260 Hp
Correction Factor 1.038 (or 3.75% hp loss) Correcting for Fuel Density When Testing Engines on a Dynamometer
When engines are tested on a dynamometer which measures actual flywheel or drive train output, the observed horsepower is dependent on the fuel used. If the fuel being used is not 35° API at 60°F, then any dynamometer readings must be corrected to determine the output if 35° API fuel had been used. The same horsepower correction factor is used, but the formula is different:Corrected Horsepower = Observed Horsepower x Horsepower Correction FactorExample:1674 Truck Engine, Serial No. 9482551Rated (full load Horsepower: 270 Horsepower)Observed (dynamometer) Horsepower: 260 HorsepowerCalculations:
Measured API gravity: 39.6° API at 50°F (round to 40° API)
Corrected API Gravity (see chart): 41° API at 60°F
Horsepower Correction Factor (see chart): 1.038
Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor 260 horsepower x 1.038 = 270 horsepower(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be operating at rated output. The factory tolerance on rated engine output is 3%.)REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form GEG01024 .Diesel Fuel API Gravity to IbsJU.S. gallon or kg/liter Conversion Chart
The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow rates can be converted
Record the corrected API gravity from this chart.Table of Horsepower Correction Factors
Table 2
Corrected API
Gravity at 60° F Precombustion
Chamber Engines Direct Injection Engines (Use the correct full load RPM)
1800 2000 2200 2400 2600 2800 3000 3200
32.0
32.5
33.0
33.5
34.0 .984
.987
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995
34.5
35.0
35.5
36.0
36.5 .997
1.000
1.003
1.005
1.008 .998
1.000
1.003
1.007
1.013 .998
1.000
1.003
1.007
1.010 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012
37.0
37.5
38.0
38.5
39.0 1.011
1.014
1.017
1.020
1.023 1.014
1.018
1.022
1.025
1.029 1.014
1.018
1.022
1.026
1.030 1.014
1.018
1.022
1.026
1.030 1.015
1.019
1.022
1.026
1.030 1.015
1.019
1.023
1.027
1.031 1.016
1.020
1.024
1.028
1.032 1.016
1.020
1.024
1.028
1.033 1.016
1.021
1.025
1.029
1.034
39.5
40.0
40.5
41.0
41.5 1.027
1.030
1.034
1.038
1.043 1.034
1.038
1.043
1.048
1.053 1.034
1.038
1.043
1.048
1.054 1.034
1.039
1.044
1.049
1.055 1.035
1.040
1.045
1.050
1.056 1.036
1.040
1.045
1.051
1.056 1.036
1.041
1.046
1.051
1.057 1.037
1.042
1.047
1.053
1.059 1.039
1.045
1.047
1.057
1.064
42.0
42.5
43.0
43.5
44.0 1.047
1.053
1.060
1.067
1.076 1.059
1.066
1.073
1.082
1.095 1.060
1.067
1.074
1.084
1.096 1.061
1.068
1.076
1.085
1.098 1.062
1.069
1.077
1.086
1.099 1.063
1.070
1.078
1.087
1.100 1.064
1.071
1.079
1.088
1.102 1.066
1.072
1.081
1.091
1.105 1.072
1.080
1.089
1.099
1.115 Use the above chart to find the horsepower correction factor.Calculating the Corrected Horsepower
Determine the rated full load horsepower from the Rack Setting Information Book.
Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the corrected horsepower.Example:1674 - Truck Engine Serial No. 94B2551Rated Horsepower: 270 HorsepowerCalculations:
Table 3
1. Measured API gravity: 40.4' API at 50' (round to 40' API)
2. Corrected API gravity (see chart): 41' API at 60'F
3. Hpr correction factor (see chart): 1.038
4. Corrected Hp = Rated Hpr = 270 = 260 Hp
Correction Factor 1.038 (or 3.75% hp loss) Correcting for Fuel Density When Testing Engines on a Dynamometer
When engines are tested on a dynamometer which measures actual flywheel or drive train output, the observed horsepower is dependent on the fuel used. If the fuel being used is not 35° API at 60°F, then any dynamometer readings must be corrected to determine the output if 35° API fuel had been used. The same horsepower correction factor is used, but the formula is different:Corrected Horsepower = Observed Horsepower x Horsepower Correction FactorExample:1674 Truck Engine, Serial No. 9482551Rated (full load Horsepower: 270 Horsepower)Observed (dynamometer) Horsepower: 260 HorsepowerCalculations:
Measured API gravity: 39.6° API at 50°F (round to 40° API)
Corrected API Gravity (see chart): 41° API at 60°F
Horsepower Correction Factor (see chart): 1.038
Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor 260 horsepower x 1.038 = 270 horsepower(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be operating at rated output. The factory tolerance on rated engine output is 3%.)REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form GEG01024 .Diesel Fuel API Gravity to IbsJU.S. gallon or kg/liter Conversion Chart
The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow rates can be converted