106671-8592 ZEXEL 9 400 617 005 BOSCH INJECTION-PUMP ASSEMBLY 9400617005 1066718592 220008041b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 005 9400617005

ZEXEL 106671-8592 1066718592

HINO 220008041B 220008041b

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Buy INJECTION-PUMP ASSEMBLY 106671-8592 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-8592 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-7780

3. GOVERNOR 105921-6272

4. SUPPLY PUMP 105217-1910

5. AUTOM. ADVANCE MECHANIS 105681-5150

6. COUPLING PLATE 105663-0620

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7483

11. Nozzle and Holder 23600-2520C

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105031-7241

14. NOZZLE

15. NOZZLE SET 105019-0190

Include in #1:

106671-8592 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 005 9400617005

ZEXEL 106671-8592 1066718592

HINO 220008041B 220008041b

Zexel num

Bosch num

Firm num

Name

106671-8592

9 400 617 005

220008041B HINO

INJECTION-PUMP ASSEMBLY
K13D 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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.6 4.54 4.6

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 126 132

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 6.5+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8.5 5.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 127 131

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 135 129 141

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 122 116 128

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-1.1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 75 69 81

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 165 165 185

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 695--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 645

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (800)

Advance angle deg. 1 0.7 1.3

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 860+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1075-50

Advance angle deg. 5.5 5.2 5.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=J28
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=47mm
----------
a=18.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper screw at speed lever full position, pump speed bb and rack position cc . Then, confirm non-injection and measure the actual rack position at idle speed dd. After adjustment, apply red paint.
----------
aa=40mm bb=1150r/min cc=4.2-0.5mm dd=225r/min
----------
a=31deg+-5deg b=(40deg)+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(3deg)

Information:

Install Tooling (E). Tighten Tooling (E) to a torque of 9 1 N m (80 9 lb in).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 6 g02025176
Disconnect harness assemblies (3).
Remove nut (5) and remove the clamp assembly. Discard the clamp assembly.
Loosen nuts (4) and (7). Remove the fuel line and discard the fuel line.
Disconnect hose assembly (6).
Illustration 7 g02029098
Disconnect tube assemblies (9).
Disconnect hose assemblies (10) and (11).
Remove bolts (8).
Illustration 8 g02029093
Disconnect tube assembly (12).
Illustration 9 g02025262
Remove bolts (13) and remove fuel pump (14).Installing the Fuel Injection Pump
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
Illustration 10 g02385860
Service replacement pump
Note: Service replacement pump is shipped pinned with warning tag (Z) installed under pinch bolt (E).
Illustration 11 g02025262
Position fuel pump (14) and install bolts (13).
Illustration 12 g02029093
Connect tube assembly (12).
Illustration 13 g02029098
Install bolts (8).
Connect tube assembly (9) and connect both hose assemblies (10) and (11).
Illustration 14 g02025176Note: During installation, make sure that the fuel line caps remain in position until the fuel line is positioned near the corresponding ports in order to prevent contamination. Ensure that the areas around the rail and fuel lines are thoroughly clean before continuing this procedure. If any parts are worn or damaged, use new parts for replacement. Cleanliness is an important factor. Ensure that no debris gets introduced into the fuel system during the installation procedure. If any parts are worn or damaged, use new parts for replacement.
Connect harness assemblies (3).
Install a new fuel line. Hand tighten nuts (4) and (7).
Position the clamp assembly and install nut (5). Hand tighten the nut. Failure to place the grommet correctly on the fuel line could result in a failed fuel line.Note: Ensure that the fuel lines are centered in the nuts prior to tightening. Do not use excessive force or bending in order to assemble the fuel lines.
Tighten nut (4) at the fuel rail to a torque of 27 3 N m (239 27 lb in).
Tighten nut (7) to a torque of 27 3 N m (239 27 lb in).
Tighten nut (5) to a torque of 12 3 N m (105 27 lb in).
Illustration 15 g02351995
Remove Tooling (E) and warning tag (Z).Note: The pump will not function while Tooling (E) is installed. Running the fuel injection pump with the tooling installed will result in pump damage and system contamination.
Illustration 16 g02351981
Install O-ring seal (2) and plug (1). Tighten the plug to a torque of 9 1 N m (80 9 lb in).
Illustration 17 g02112896
Remove all tooling. Reinstall plug (X) into the timing hole that is located in the flywheel housing.
Connect Caterpillar Electronic Technician (ET). Perform a “Fuel System Functional Test ”and a “Fuel System Verification Test”.