106685-4481 ZEXEL 9 400 613 446 BOSCH INJECTION-PUMP ASSEMBLY 9400613446 1066854481 6212721110

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 446 9400613446

ZEXEL 106685-4481 1066854481

KOMATSU 6212721110 6212721110

Service parts 106685-4481 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-4210

3. GOVERNOR 105447-2531

4. SUPPLY PUMP 105237-1621

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0340

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4680

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 24.5{250}

13. NOZZLE-HOLDER 105041-7122

14. NOZZLE 105025-0940

15. NOZZLE SET

Include in #1:

106685-4481 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 446 9400613446

ZEXEL 106685-4481 1066854481

KOMATSU 6212721110 6212721110

Zexel num

Bosch num

Firm num

Name

106685-4481

9 400 613 446

6212721110 KOMATSU

INJECTION-PUMP ASSEMBLY
SDA6D140 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.3 3.25 3.35

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 11.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 308 303 313

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

Injection quantity adjustment_02

Adjusting point B

Rack position 7.7+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 19 17.5 20.5

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 12++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 275 265 285

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-2

Boost pressure kPa 32 29.3 34.7

Boost pressure mmHg 240 220 260

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(12.7)

Boost pressure kPa 70.6 70.6 70.6

Boost pressure mmHg 530 530 530

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)RACK LIMIT (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2
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K=22 N1=1000r/min N2=700r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Base lever only (2)Stopper bolt setting
----------

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a=27deg+-5deg b=36deg+-3deg c=37deg+-5deg

0000001501 GOVERNOR IDLE SUB SPRING

f : Installation load ON 2 stage idle sub-spring simultaneous setting method 1. (1) Remove the idling sub spring capsule from the governor. (2)Tighten the screw (A) until it contacts the spring (B) (that is, until the set force is generated). (3)Return to speed N1. (4)Set so that the set force is zero. (5)Fix using the lock nut (C). 2. Set the idle sub spring capsule adjusted as per (1) 1. (2)Same as the normal 1 stage idle sub spring. (3)Set so that it satisfies the governor adjustment standards. (4)Do not loosen lock nut (C) at this time.
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N1=1/2
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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)-
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aa=19deg
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a=(10deg)