Information injection-pump assembly
BOSCH
9 400 611 540
9400611540
ZEXEL
106682-9970
1066829970
KOMATSU
6152751351
6152751351

Rating:
Service parts 106682-9970 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
8.
_
9.
_
11.
Nozzle and Holder
6152-15-3600
12.
Open Pre:MPa(Kqf/cm2)
26.0{265}
15.
NOZZLE SET
Include in #1:
106682-9970
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 540
9400611540
ZEXEL
106682-9970
1066829970
KOMATSU
6152751351
6152751351
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
131425-2120
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
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
3.3
3.25
3.35
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
14.7
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
426
421
431
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
119
119
Boost pressure
mmHg
890
890
Injection quantity adjustment_02
Adjusting point
B
Rack position
7+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
29.5
27.5
31.5
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
R1-3.5
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(14.7)
Boost pressure
kPa
105
98.3
111.7
Boost pressure
mmHg
790
740
840
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
(4)Stop lever at stopping (with the speed lever at full)
----------
K=5
----------
----------
K=5
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=36deg+-5deg
----------
----------
a=4deg+-5deg b=36deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
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)B.T.D.C.: aa
(4)-
----------
aa=25deg
----------
a=(150deg)
----------
aa=25deg
----------
a=(150deg)
Information:
To Remove and Install Injection Nozzles
Refer to the Service Manual for your engine to remove and install injection nozzles.Air Compressor
Rebuild or Exchange
Visually check for fluid leaks.Our recommendation to maintain the air compressor before it fails will be less costly to you than repairing the air compressor after failure.If you operate the engine until the air compressor fails, you could cause additional damage to your engine. For example: A failed air compressor could contaminate the engine oil with foriegn material since engine oil also lubricates the air compressor. The circulation of these contaminates through the engine lubricating system could damage the engine's main and connecting rod bearings.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts, special tools and instructions to repair your air compressor in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. Exchange - This is a cost cutting service that permits you to exchange your worn air compressor for a dealer or OEM factory rebuilt air compressor on an over-the-counter basis. They are available when you need them at a substantial savings in both time and money. New - Replace with a new air compressor.Caterpillar Recommendation
The most cost effective repair option is to rebuild the air compressor with a repair kit that can be obtained from your Caterpillar dealer. Refer to the Service Manual for your engine to remove and install the air compressor.Turbocharger
Rebuild or Exchange
If you operate the engine until the turbocharger fails, you could cause severe damage to the turbocharger's compressor wheel and/or your engine. For example: severe damage to the turbocharger compressor wheel could cause parts from the compressor wheel to enter the engine cylinder and cause additional damage to the piston, valve and cylinder head.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair your turbocharger in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts costs. Remanufactured - This process uses manufacturing techniques and procedures to restore your turbocharger to "like-new" performance capability. This process always involves an end product which conforms to the manufacturer's original functional specification. New - Replace with a new turbocharger.Before deciding which method is best, you should make sure you have considered all of the options and costs associated with repair. Some considerations are: * The costs associated with using separate parts from inventory versus the cost of a repair kit.* Downtime costs while the product is being rebuilt or repaired.* Total parts and labor costs for repairs versus the actual Remanufactured cost.* Remanufactured components from Caterpillar are covered by a national factory warranty.Caterpillar Recommendation
To minimize downtime, Caterpillar recommends the use of a Remanufactured turbocharger.There are two levels of pricing for Remanufactured turbochargers.* The first level is primarily based on damage to
Refer to the Service Manual for your engine to remove and install injection nozzles.Air Compressor
Rebuild or Exchange
Visually check for fluid leaks.Our recommendation to maintain the air compressor before it fails will be less costly to you than repairing the air compressor after failure.If you operate the engine until the air compressor fails, you could cause additional damage to your engine. For example: A failed air compressor could contaminate the engine oil with foriegn material since engine oil also lubricates the air compressor. The circulation of these contaminates through the engine lubricating system could damage the engine's main and connecting rod bearings.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts, special tools and instructions to repair your air compressor in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. Exchange - This is a cost cutting service that permits you to exchange your worn air compressor for a dealer or OEM factory rebuilt air compressor on an over-the-counter basis. They are available when you need them at a substantial savings in both time and money. New - Replace with a new air compressor.Caterpillar Recommendation
The most cost effective repair option is to rebuild the air compressor with a repair kit that can be obtained from your Caterpillar dealer. Refer to the Service Manual for your engine to remove and install the air compressor.Turbocharger
Rebuild or Exchange
If you operate the engine until the turbocharger fails, you could cause severe damage to the turbocharger's compressor wheel and/or your engine. For example: severe damage to the turbocharger compressor wheel could cause parts from the compressor wheel to enter the engine cylinder and cause additional damage to the piston, valve and cylinder head.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair your turbocharger in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts costs. Remanufactured - This process uses manufacturing techniques and procedures to restore your turbocharger to "like-new" performance capability. This process always involves an end product which conforms to the manufacturer's original functional specification. New - Replace with a new turbocharger.Before deciding which method is best, you should make sure you have considered all of the options and costs associated with repair. Some considerations are: * The costs associated with using separate parts from inventory versus the cost of a repair kit.* Downtime costs while the product is being rebuilt or repaired.* Total parts and labor costs for repairs versus the actual Remanufactured cost.* Remanufactured components from Caterpillar are covered by a national factory warranty.Caterpillar Recommendation
To minimize downtime, Caterpillar recommends the use of a Remanufactured turbocharger.There are two levels of pricing for Remanufactured turbochargers.* The first level is primarily based on damage to