106682-3102 ZEXEL 9 400 617 525 BOSCH INJECTION-PUMP ASSEMBLY 9400617525 1066823102 220206152a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 617 525 9400617525

ZEXEL 106682-3102 1066823102

HINO 220206152A 220206152a

Service parts 106682-3102 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-3921

3. GOVERNOR 105407-7921

4. SUPPLY PUMP 105237-5680

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0970

7. COUPLING PLATE 156639-3420

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8630

11. Nozzle and Holder 23600-3440A

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

13. NOZZLE-HOLDER 105030-3711

14. NOZZLE

15. NOZZLE SET 105019-2740

Include in #1:

106682-3102 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 525 9400617525

ZEXEL 106682-3102 1066823102

HINO 220206152A 220206152a

Zexel num

Bosch num

Firm num

Name

106682-3102

9 400 617 525

220206152A 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 14.7

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 429 426 432

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 200 200

Boost pressure mmHg 1500 1500

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 11 9 13

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_03

Adjusting point D

Rack position R1(10.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 191 188 194

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1(10.8)

Boost pressure kPa 41.3 38.6 44

Boost pressure mmHg 310 290 330

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2(14.7)

Boost pressure kPa 187 187 187

Boost pressure mmHg 1400 1400 1400

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
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K=14 L1=16+-0.1mm BCL=(3.9)mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=22deg+-5deg b=40deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Use the hole at R = aa (3)Contacts inner boss. (4)Contacts outer boss.
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aa=23mm
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a=27deg+-5deg b=53deg+-5deg c=(11deg)

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Use the hole at R = bb (3)Stopper bolt setting (4)Drive side
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aa=16+-0.1mm bb=30mm
----------
a=(20deg) b=(15deg)

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A (B) branch piping Fuel inlet C Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
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a=(50deg)