101609-3301 ZEXEL 9 400 615 897 BOSCH INJECTION-PUMP ASSEMBLY 9400615897 1016093301 3863452

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 897 9400615897

ZEXEL 101609-3301 1016093301

KOMATSU 3863452 3863452

Service parts 101609-3301 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5170

4. SUPPLY PUMP 105220-5690

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101609-3301 as INJECTION-PUMP ASSEMBLY

Include in #2:

104257-1090 as _

Cross reference number

BOSCH 9 400 615 897 9400615897

ZEXEL 101609-3301 1016093301

KOMATSU 3863452 3863452

Zexel num

Bosch num

Firm num

Name

101609-3301

9 400 615 897

3863452 KOMATSU

INJECTION-PUMP ASSEMBLY
6BT-C K

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 131424-3420

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 2.5 2.45 2.55

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 8.9

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 81 80 82

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.4+-0.5

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 15 14 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position R1-0.5

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position R1(8.9)

Boost pressure kPa 29.3 22.6 36

Boost pressure mmHg 220 170 270

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Set idle sub-spring (7)Main spring setting (8)Boost compensator stroke: BCL (9)When hydraulic cylinder ON: P1
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K=10 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At hole at R = aa (center)
----------
aa=80mm
----------
a=36deg+-3deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
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aa=18deg bb=0deg
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a=54deg54min+-3deg b=9deg+-30min