101601-3100 ZEXEL 9 400 610 243 BOSCH INJECTION-PUMP ASSEMBLY 9400610243 1016013100 6138721600

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 243 9400610243

ZEXEL 101601-3100 1016013100

KOMATSU 6138721600 6138721600

Service parts 101601-3100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2700

3. GOVERNOR 105411-0840

4. SUPPLY PUMP 105210-4690

5. AUTOM. ADVANCE MECHANIS 105614-3070

6. COUPLING PLATE 105662-0810

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6000

11. Nozzle and Holder 6138-12-3100

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

13. NOZZLE-HOLDER 105031-4480

14. NOZZLE 105015-5680

15. NOZZLE SET

Include in #1:

101601-3100 as INJECTION-PUMP ASSEMBLY

101692-3772 as _

Cross reference number

BOSCH 9 400 610 243 9400610243

ZEXEL 101601-3100 1016013100

KOMATSU 6138721600 6138721600

Zexel num

Bosch num

Firm num

Name

101601-3100

9 400 610 243

6138721600 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D110 K 14BF INJECTION PUMP ASSY PE6AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

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 4 3.95 4.05

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 9.9

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 76 75 77

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_02

Adjusting point B

Rack position 10.9

Pump speed r/min 725 725 725

Average injection quantity mm3/st. 85 83 87

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_03

Adjusting point C

Rack position 7.3+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13 11.8 14.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position 10

Boost pressure kPa 12 10.7 13.3

Boost pressure mmHg 90 80 100

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position 10.9

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1050

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator stroke
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K=7
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=12deg+-5deg b=26deg+-5deg c=32deg+-3deg

0000001501 LEVER

(F) P/N: Part number of the shim L1:Thickness (mm) 1. Adjustment of the control lever (1)Perform idling with the control lever (A) contacting the pushrod (B). At this time, confirm that the spring (C) is not compressed by control lever (A)'s operating torque. (2)To set the stop position, compress spring (C) using the control lever (A) and adjust the rack so that it contacts the guide screw (D) at position L2. Then, set and fix using the lock nut (E). Adjust the rack position L2 at this time using the shim (F). (3)Confirm that the control lever (A) returns to the idling position when pulled in the stop direction and then released.
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L2=0.2~2mm
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