Information injection-pump assembly
BOSCH
9 400 619 961
9400619961
ZEXEL
106682-9861
1066829861
KOMATSU
6152751280
6152751280
Rating:
Service parts 106682-9861 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106682-9861
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 961
9400619961
ZEXEL
106682-9861
1066829861
KOMATSU
6152751280
6152751280
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131425-1620
Overflow valve opening pressure
kPa
255
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
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
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
15.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
411
408
414
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
131
131
Boost pressure
mmHg
980
980
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
19
17
21
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
600
600
600
Rack position
R1-3.9
Boost pressure
kPa
30.7
28
33.4
Boost pressure
mmHg
230
210
250
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(15.5)
Boost pressure
kPa
117
110.3
123.7
Boost pressure
mmHg
880
830
930
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 stroke: BCL
(4)Stop lever at stopping (with the stop lever at full)
----------
K=10 BCL=3.9+-0.1mm
----------
----------
K=10 BCL=3.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=90mm
----------
a=4deg+-5deg b=36deg+-5deg
----------
aa=90mm
----------
a=4deg+-5deg b=36deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(150deg)
----------
----------
a=(150deg)
Information:
New Dipsticks With Full Range Readings
The new rear sump and front sump dipsticks are used with their respective oil pans. These oil pans are used in truck applications with set-back axles.The new dipsticks are different because they have a FULL RANGE zone versus other dipsticks that have the traditional FULL mark. These dipsticks are used for truck applications with various angles and slants of engine installation (angle = front to back tilt, slant = sideways tilt).Calibration
Use the following procedure to calibrate FULL RANGE dipsticks. A convenient time to calibrate the dipstick is at the first oil change.Refer to the PM Level 1 of the Maintenance Management Schedule of this publication for the proper oil change interval.To verify the "ADD" mark and establish the actual "FULL" mark, use the following procedure: Truck must be parked on a level surface.1. Operate the engine until it reaches normal operating temperature.2. Stop the engine. Drain the oil and change the oil filter.3. Fill the crankcase with 32 U.S. quarts (30.3 liters) of oil. Brakesaver models require 36 quarts (34 L). Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.4. Allow the oil to drain back to the sump for a minimum of five minutes.5. Remove the dipstick. The oil level should be at the ADD mark. If it is not, mark the actual level on the dipstick. This is now the correct ADD mark.6. Add an additional 4 U.S. quarts (3.8 liters) of oil to the sump. Allow enough time for the oil to drain into the sump. Again, check the level on the dipstick.7. This is the correct FULL mark in the FULL RANGE zone on the dipstick. If it is not, mark the new FULL level on the dipstick. Remote mounted or auxiliary filters require additional oil also. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.8. Start the engine and operate until it reaches normal operating temperature. Stop the engine.9. Allow the oil to drain back to the sump for a minimum of 10 minutes.10. Remove the dipstick. The oil level should be near the FULL mark. If it is not, add oil until the level reaches the FULL mark on the dipstick.This procedure is correct for use with either the non-spacer plate oil pan or the spacer plate oil pan. Sump capacities and oil levels are the same for each oil pan.Any FULL RANGE dipstick for the 3406B Truck engine can be calibrated using this procedure.
The new rear sump and front sump dipsticks are used with their respective oil pans. These oil pans are used in truck applications with set-back axles.The new dipsticks are different because they have a FULL RANGE zone versus other dipsticks that have the traditional FULL mark. These dipsticks are used for truck applications with various angles and slants of engine installation (angle = front to back tilt, slant = sideways tilt).Calibration
Use the following procedure to calibrate FULL RANGE dipsticks. A convenient time to calibrate the dipstick is at the first oil change.Refer to the PM Level 1 of the Maintenance Management Schedule of this publication for the proper oil change interval.To verify the "ADD" mark and establish the actual "FULL" mark, use the following procedure: Truck must be parked on a level surface.1. Operate the engine until it reaches normal operating temperature.2. Stop the engine. Drain the oil and change the oil filter.3. Fill the crankcase with 32 U.S. quarts (30.3 liters) of oil. Brakesaver models require 36 quarts (34 L). Remote mounted or auxiliary filters require additional oil. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.4. Allow the oil to drain back to the sump for a minimum of five minutes.5. Remove the dipstick. The oil level should be at the ADD mark. If it is not, mark the actual level on the dipstick. This is now the correct ADD mark.6. Add an additional 4 U.S. quarts (3.8 liters) of oil to the sump. Allow enough time for the oil to drain into the sump. Again, check the level on the dipstick.7. This is the correct FULL mark in the FULL RANGE zone on the dipstick. If it is not, mark the new FULL level on the dipstick. Remote mounted or auxiliary filters require additional oil also. For all information pertaining to auxiliary oil filters, refer to the OEM or manufacturer's instructions.8. Start the engine and operate until it reaches normal operating temperature. Stop the engine.9. Allow the oil to drain back to the sump for a minimum of 10 minutes.10. Remove the dipstick. The oil level should be near the FULL mark. If it is not, add oil until the level reaches the FULL mark on the dipstick.This procedure is correct for use with either the non-spacer plate oil pan or the spacer plate oil pan. Sump capacities and oil levels are the same for each oil pan.Any FULL RANGE dipstick for the 3406B Truck engine can be calibrated using this procedure.