101609-3102 ZEXEL 9 400 610 772 BOSCH INJECTION-PUMP ASSEMBLY 9400610772 1016093102 6221711230

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 772 9400610772

ZEXEL 101609-3102 1016093102

KOMATSU 6221711230 6221711230

Service parts 101609-3102 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8570

3. GOVERNOR 105411-1651

4. SUPPLY PUMP 105210-5040

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5100

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 23.0{235}

13. NOZZLE-HOLDER 105048-3560

14. NOZZLE

105017-1120

15. NOZZLE SET

Include in #1:

101609-3102 as INJECTION-PUMP ASSEMBLY

Include in #2:

104244-8072 as _

Cross reference number

BOSCH 9 400 610 772 9400610772

ZEXEL 101609-3102 1016093102

KOMATSU 6221711230 6221711230

Zexel num

Bosch num

Firm num

Name

101609-3102

9 400 610 772

6221711230 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D108 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

Overflow valve 131424-1520

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)
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 3.6 3.55 3.65

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 11.3

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 103 102 104

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_02

Adjusting point B

Rack position 6.4+-0.5

Pump speed r/min 415 415 415

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

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 200 195 205

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position 10.6

Boost pressure kPa 2.7 1.4 4

Boost pressure mmHg 20 10 30

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 12.1

Boost pressure kPa 36 29.3 42.7

Boost pressure mmHg 270 220 320

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)RACK LIMIT (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2
----------
K=10 N1=1100r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=9deg+-5deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed = aa and rack position = bb, set the stopper bolt (to be sealed at delivery).
----------
aa=0r/min bb=1-0.5mm
----------
a=42.5deg+-5deg b=(55deg)