106682-9610 ZEXEL 9 400 612 402 BOSCH INJECTION-PUMP ASSEMBLY 9400612402 1066829610 6166711531

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 402 9400612402

ZEXEL 106682-9610 1066829610

KOMATSU 6166711531 6166711531

Service parts 106682-9610 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2581

3. GOVERNOR 105447-1970

4. SUPPLY PUMP 105237-4510

5. AUTOM. ADVANCE MECHANIS 105649-0101

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:

106682-9610 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 402 9400612402

ZEXEL 106682-9610 1066829610

KOMATSU 6166711531 6166711531

Zexel num

Bosch num

Firm num

Name

106682-9610

9 400 612 402

6166711531 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 15.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 395 390 400

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 R1-2.2

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(17.1)

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 for 106684-4170 (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 BCL=2.2+-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 (1)Stopper bolt setting
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a=(19deg)+-5deg b=33deg+-3deg c=(31deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed 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)Position the rack at L2. (Adjustment is performed using the shim (F).) (3)Set and fix using lock nut (E) so that it contacts the guide screw (D). 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)