106682-9151 ZEXEL 9 400 610 972 BOSCH INJECTION-PUMP ASSEMBLY 9400610972 1066829151 6166711521

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 972 9400610972

ZEXEL 106682-9151 1066829151

KOMATSU 6166711521 6166711521

Service parts 106682-9151 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2580

3. GOVERNOR 105447-1590

4. SUPPLY PUMP 105237-4510

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4442

11. Nozzle and Holder 6162-13-3701

12. Open Pre:MPa(Kqf/cm2) 26.0{265}

13. NOZZLE-HOLDER 105041-7102

14. NOZZLE 105015-8600

15. NOZZLE SET

Include in #1:

106682-9151 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 972 9400610972

ZEXEL 106682-9151 1066829151

KOMATSU 6166711521 6166711521

Zexel num

Bosch num

Firm num

Name

106682-9151

9 400 610 972

6166711521 KOMATSU

INJECTION-PUMP ASSEMBLY
SA12V170 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 131425-1620

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 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 1-5-3-6- 2-4

Pre-stroke mm 2.8 2.75 2.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 16.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 425 420 430

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Remarks
Standard point A's rack position same as row R

Injection quantity adjustment_02

Adjusting point C

Rack position 7.1+-0.5

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 31 26 36

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-3

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(18.3)

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (set using 106684-4160) (3)Boost compensator stroke: BCL (4)Rack difference between N = N1 and N = N2 (5)Idle sub spring setting: L1.
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K=20 RAL=18.8+0.2mm BCL=3+-0.1mm N1=900r/min N2=650r/min L1=6.8-0.5mm
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=19deg+-5deg b=31deg+-5deg c=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Seal at delivery.)
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aa=0r/min bb=1-0.5mm
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a=29deg+-5deg b=(73deg)

0000001501 LEVER

Speed lever adjustment 1. (1) For idling hold the speed lever (a) against the push rod (B). (2)At this time, confirm that the spring (C) is not bent by the operating torque of the speed lever. 2. (1) To stop, bend the spring (C) using the speed lever. (2)Set so that the rack position is L2. (3)Set and fix using lock nut (E) so that it contacts the guide screw (D). (4)Adjust rack position at this time using shim (F). 3. Confirm that the speed lever returns to the idling position when pulled in the stop direction and then released.
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L2=0.2~2mm
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Timing setting

(1)Pump vertical direction (2)Position of spline gear's aligning mark at No 1 cylinder's beginning of injection (key position) (3)B.T.D.C.: aa (4)-
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aa=34deg
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a=(130deg)