106671-6770 ZEXEL 9 400 619 942 BOSCH INJECTION-PUMP ASSEMBLY 9400619942 1066716770 1156035110

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 942 9400619942

ZEXEL 106671-6770 1066716770

ISUZU 1156035110 1156035110

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Buy INJECTION-PUMP ASSEMBLY 106671-6770 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-6770 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6930

3. GOVERNOR 105407-8570

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:

106671-6770 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 942 9400619942

ZEXEL 106671-6770 1066716770

ISUZU 1156035110 1156035110

Zexel num

Bosch num

Firm num

Name

106671-6770

9 400 619 942

1156035110 ISUZU

INJECTION-PUMP ASSEMBLY
6HK1-T K 14CA INJECTION PUMP ASSY 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 11.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 121 120 122

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 147 147

Boost pressure mmHg 1100 1100

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-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 11.6++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 120 135

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 (R1-2.15 )+-0.1

Boost pressure kPa 12 9.3 14.7

Boost pressure mmHg 90 70 110

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.3)

Boost pressure kPa 133 126.3 139.7

Boost pressure mmHg 1000 950 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+-25

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)Main spring setting (7)Set idle sub-spring
----------
K=12 BCL=2.15+-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=10deg+-5deg b=31deg+-3deg c=23deg+-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 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (F) Red paint (g) Pump end face 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Select a shim D so that L = 38-0.2 mm and install rod C. (3)Release the rack fixing and mount the joint (B) and fix. (4)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (154610-4*20) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (E). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply at 2 locations (F). Joint B and nut E join Joint B and pump end face G join
----------
N1=1100r/min Ra=11.3mm
----------

0000001601 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)

Information:

Introduction
The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.Required Tools
Table 1
Required Tools
Part Number Part Name Quantity
380-5200 Tool Kit 1 Testing Procedure
Perform a “Manual Diesel Particulate Filter Regeneration” using Caterpillar Electronic Technician (Cat ® ET).
After the manual DPF regeneration is complete, run the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Illustration 1 g02597531
(1) DPF Outlet Cap
(2) Filter Paper
(3) Hose Assembly
(4) Air Pump
Illustration 2 g02599276
(5) DPF Outlet Port
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut down the engine and remove the Delta P line from the DPF outlet port. Refer to Illustrations 1 and 2.
Illustration 3 g02599418
(6) Filter Paper
Install the filter in the fitting, Refer to Illustration 3. Install the fitting in the DPF outlet port. The filter must be installed in less than 10 minutes after the engine has shut down.
Turn the vacuum pump ON.
Disable automatic regeneration in Cat ET.
Illustration 4 g02597737
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Disabled". The check engine light and a 3714-31 active code will be present.
Override the "DPF Differential Pressure Line Override" to "Disconnected", using Cat ET. Refer to Illustration 4.
Start the engine. Run the engine at 1800 rpm for 15 minutes.Note: Manually set the engine speed to 1800 rpm, the engine must maintain a steady speed for the entire duration of the test.
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Shut the engine down and remove the filter holder within 25 minutes. Use proper personal protective equipment to remove the filter holder.
Allow the filter holder time to cool down before disassembly.
Carefully disassemble the filter holder to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.
Illustration 5 g02597796
Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
If the shade is equal to or darker than the "Color Code Sheet", the DPF has a crack or leak. Replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".
If the shade is lighter than the "Color Code Sheet", then return the unit to service.
Enable the Automatic regeneration in Cat ET.
Select "Service" - "Configuration" - "Emissions Parameters" and "ARD Manual Disable Status". Select "Not - Disabled". The check engine light will go off unless