106689-4040 ZEXEL 9 400 617 739 BOSCH INJECTION-PUMP ASSEMBLY 9400617739 1066894040 6215711260

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 739 9400617739

ZEXEL 106689-4040 1066894040

KOMATSU 6215711260 6215711260

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Cross reference number

BOSCH 9 400 617 739 9400617739

ZEXEL 106689-4040 1066894040

KOMATSU 6215711260 6215711260

Zexel num

Bosch num

Firm num

Name

106689-4040

9 400 617 739

6215711260 KOMATSU

INJECTION-PUMP ASSEMBLY
SA12V140 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 8-3-600

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 14.7

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 322 319 325

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Remarks
Standard point A's rack position same as 106681-4130 in row L

Injection quantity adjustment_02

Adjusting point -

Rack position 8.7+-0.5

Pump speed r/min 340 340 340

Average injection quantity mm3/st. 28 26.5 29.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Remarks
Rack limit setting R = 15.7+0.2

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2.5 2 3

Remarks
Measure the actual speed, stop

Test data Ex:

Timing setting

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

----------
a=(150deg)

Information:

1. Remove two bolts (1) and remove oil supply line (2). Remove two bolts (3), loosen hose clamp (4) and move drain tube (5) out of the way. 2. Remove four nuts (6). Remove the turbocharger. The following steps are for the installation of the turbocharger.3. Apply 5P3931 Anti-Seize to turbocharger mounting studs. Position turbocharger gasket and turbocharger. Install four nuts (6). Tighten nuts to a torque of 55 5 N m (40 4 lb ft).4. Position drain tube with gasket and install bolts (3), then tighten hose clamp (4). Position oil supply line (2) with gasket and install bolts (1).Disassemble & Assemble Turbocharger
Start By:a. remove turbocharger 1. Place turbocharger in tooling (A). Put alignment marks on all the housings. Loosen clamp (1) and remove housing (2). 2. Loosen clamp (3) and remove cartridge assembly (4). 3. Place cartridge assembly (4) in tooling (B).
Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (5). Do not bend or add stress to the shaft when nut (5) is loosened or tightened.
4. Remove nut (5) and remove compressor wheel (6).5. Remove snap ring (7), then use two screw drivers and remove adapter plate (8). Remove O-ring seal (9) and inspect.6. Remove and inspect bushing and seal (10).7. Remove oil deflector (11) and thrust ring (12).8. Remove bearing (13), sleeve (14) and thrust ring (15).9. Lift housing assembly (19) off of shaft and wheel (20).10. Use snap ring pliers and remove wrap around snap ring (16), then remove double bushing (17).11. Remove seal ring (21) and backplate (18).12. Check all parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instructions Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for the assembly of the turbocharger.13. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been assembled, put clean engine oil into the oil inlet of the turbocharger.14. With shaft and wheel (20) in tooling (B), install seal (21).15. Install double bushing (17) into housing (19) and install wrap around snap ring (16). Position housing assembly (19) onto shaft and wheel (20).16. Install thrust ring (15), bearing (13), sleeve (14) and thrust ring (12). Install oil deflector (11) then bushing and seal (10).17. With oil seal (9) in place, position adapter plate (8) and install snap ring (7).
Do not bend or add stress to the shaft when nut (5) is tightened.
18. Install compressor wheel (6) on the shaft. Put one drop of 9S2365 Retaining Compound on the threads of the shaft. Install nut (5) and torque it to 14.4 0.5 N m (144 5 lb in).19. Remove cartridge assembly (4) from tooling (B) and install it into the housing on tooling (A). Align marks and tighten clamp (3).20. Install