106682-9020 ZEXEL 9 400 613 081 BOSCH INJECTION-PUMP ASSEMBLY 9400613081 1066829020 6215711150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 081 9400613081

ZEXEL 106682-9020 1066829020

KOMATSU 6215711150 6215711150

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Buy INJECTION-PUMP ASSEMBLY 106682-9020 zexel genuine, new aftermarket engine parts with delivery

Service parts 106682-9020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106068-2062

3. GOVERNOR 105447-1410

4. SUPPLY PUMP 105237-1690

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0540

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4402

11. Nozzle and Holder 6212-11-3202

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

13. NOZZLE-HOLDER 105041-7122

14. NOZZLE 105015-8070

15. NOZZLE SET

Include in #1:

106682-9020 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 081 9400613081

ZEXEL 106682-9020 1066829020

KOMATSU 6215711150 6215711150

Zexel num

Bosch num

Firm num

Name

106682-9020

9 400 613 081

6215711150 KOMATSU

INJECTION-PUMP ASSEMBLY
SA12V140 K

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)
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 3.5 3.45 3.55

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 13.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 320.5 318.5 322.5

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 -

Rack position 8.4+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 20 18.5 21.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 13

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 15

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 106684-4013) (3)Boost compensator stroke (4)Set the No 1 idle sub spring. (5)Set the 2nd idle sub spring. (6)Rack difference between N = N1 and N = N2
----------
K=19 RAL=15.5+0.2mm N1=1000r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=(15deg)+-5deg b=(24deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=29deg+-5deg b=(73deg)

Timing setting

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

----------
a=(30deg)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove idler gear (7).2. Remove the gear train housing, which has the Power Take Off, (PTO), mounted to it.3. Remove bolts (3) and drive opening cover (10). Remove PTO gear assembly (1). Remove six nuts (4).4. Remove adapter assembly (2) and o-ring seals (6) and (8).5. If necessary, remove bearing sleeves (9) and (5) for the idler gear and the PTO gear (1). Make note of the positioning of the oil holes in the bearings. Proper location of the holes during installation is necessary for lubrication. The following steps are for the installation of the PTO Assembly.6. Install bearing sleeves (5) and (9). Be sure to align oil holes.7. Install PTO assembly in the gear train housing. Coat the bearing sleeves with clean engine oil. Install o-ring seal (8). Position adapter assembly (2) on the studs and install the nuts8. Install o-ring seal (6), drive opening cover (10) and bolts (3).9. Install the gear train housing on the engine block.10. Install the idler gear. Apply 5P3414 Pipe Sealant to the threads of the bolts and install. Torque to 135 15 N m (100 11 lb ft).
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.
End By:a. install flywheel housing