101601-3400 ZEXEL 9 400 614 582 BOSCH INJECTION-PUMP ASSEMBLY 9400614582 1016013400 6138721350

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 582 9400614582

ZEXEL 101601-3400 1016013400

KOMATSU 6138721350 6138721350

Service parts 101601-3400 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2700

3. GOVERNOR 105411-1280

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 105100-6180

11. Nozzle and Holder 6138-12-3300

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

13. NOZZLE-HOLDER 105031-4480

14. NOZZLE

105015-5810

15. NOZZLE SET

Include in #1:

101601-3400 as INJECTION-PUMP ASSEMBLY

106672-9183 as _

Cross reference number

BOSCH 9 400 614 582 9400614582

ZEXEL 101601-3400 1016013400

KOMATSU 6138721350 6138721350

Zexel num

Bosch num

Firm num

Name

101601-3400
101601-3520

9 400 614 582

6138721350 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D110 K 14BE INJECTION PUMP ASSY PE6A 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 10.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 86.1 85.1 87.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_02

Adjusting point B

Rack position 7.4+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 15.5 14.3 16.7

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 600 600 600

Rack position 9.9

Boost pressure kPa 5.3 2.6 8

Boost pressure mmHg 40 20 60

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 11.1

Boost pressure kPa 30.7 30.7 30.7

Boost pressure mmHg 230 230 230

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 1100

Advance angle deg. 3.2 2.7 3.7

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 (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
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K=13 N1=1100r/min N2=750r/min N3=1100r/min N4=400r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=6deg+-5deg b=20deg+-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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