106682-3091 ZEXEL 9 400 612 545 BOSCH INJECTION-PUMP ASSEMBLY 9400612545 1066823091 220206041a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 545 9400612545

ZEXEL 106682-3091 1066823091

HINO 220206041A 220206041a

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Buy INJECTION-PUMP ASSEMBLY 106682-3091 zexel genuine, new aftermarket engine parts with delivery

Service parts 106682-3091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-3520

3. GOVERNOR 105407-7690

4. SUPPLY PUMP 105237-5520

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0970

7. COUPLING PLATE 156639-3420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8551

11. Nozzle and Holder 23600-3360B

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-3531

14. NOZZLE

15. NOZZLE SET 105019-2470

Include in #1:

106682-3091 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 545 9400612545

ZEXEL 106682-3091 1066823091

HINO 220206041A 220206041a

Zexel num

Bosch num

Firm num

Name

106682-3091

9 400 612 545

220206041A HINO

INJECTION-PUMP ASSEMBLY
P11B-TI 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 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000

Overflow valve 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.3 3.27 3.33

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 A

Rack position 14.2

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 407 404 410

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 120 120

Boost pressure mmHg 900 900

Injection quantity adjustment_02

Adjusting point B

Rack position R2(10.65 )

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 187 184 190

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 6.1+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 8 6 10

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point E

Rack position (16.5)+- 0.1

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 425 415 435

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Boost compensatory excess lever at excess.

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(10.65 )

Boost pressure kPa 26.7 24 29.4

Boost pressure mmHg 200 180 220

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(14.2)

Boost pressure kPa 107 107 107

Boost pressure mmHg 800 800 800

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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting (7)Damper spring setting
----------
K=7 L1=(16.5)+-0.1mm BCL=(3.55)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=7deg+-5deg b=33deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Contacts inner boss. (3)Contacts outer boss.
----------

----------
a=27deg+-5deg b=53deg+-5deg c=(11deg)

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
----------
aa=(16.5)+-0.1mm
----------
a=(16deg) b=(15deg)

Timing setting

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

----------
a=(50deg)

Information:

Remove Brakesaver Control Valve
1. Drain the oil from the oil pan. 2. Remove two short bolts (1) and two longer bolts (3) from manifold (2) and BrakeSaver housing. Remove manifold (2). Remove the O-ring seals from the manifold. 3. Remove oil temperature sensing unit (4) from the BrakeSaver control valve.4. Disconnect air line (5) and hose assembly (6) from the BrakeSaver control valve. 5. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve. 6. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve. 7. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is 48 lb. (22 kg).8. Remove elbow (13) from the BrakeSaver control valve. Remove the O-ring seals.Install Brakesaver Control Valve
1. Inspect the O-ring seals for damage and make replacements if needed. Put clean oil on the O-ring seals. 2. Install the O-ring seals and elbow (3) on the BrakeSaver control valve.3. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (1) in position under the oil pan. Install bolts (2) that hold the BrakeSaver control valve to the oil pan. 4. Install oil temperature sensing unit (4) in the BrakeSaver control valve.5. Connect air line (5) and hose assembly (6) to the BrakeSaver control valve. 6. Install O-ring seals (7) and (8) on manifold (9). Install manifold (9) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing. 7. Make sure the O-ring seals are in place on the oil lines and install oil lines (10) and (11). 8. Install retainer (12) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Pipe Sealant on the threads and tighten the plug to a torque of 60 8 lb. ft. (80 11 N m).9. Fill the engine with oil. See LUBRICATION AND MAINTENANCE GUIDE.Disassemble Brakesaver Control Valve
start by:a) remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.
Spring force is behind the cover at removal.
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the O-ring seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Make an inspection of the pin on the spool, and make a replacement of the pin if there is damage or wear.Assemble Brakesaver Control Valve
1. Install diaphragm (4) and plate (8) on valve spool (3). Make alignment of the hole in the