101609-3530 ZEXEL 9 400 611 525 BOSCH INJECTION-PUMP ASSEMBLY 9400611525 1016093530 6221731230

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 525 9400611525

ZEXEL 101609-3530 1016093530

KOMATSU 6221731230 6221731230

Service parts 101609-3530 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8860

3. GOVERNOR 105411-2050

4. SUPPLY PUMP 105210-6260

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6130

11. Nozzle and Holder 6221-13-3300

12. Open Pre:MPa(Kqf/cm2) 20.6{210}

13. NOZZLE-HOLDER 105048-3560

14. NOZZLE 105017-1960

15. NOZZLE SET

Include in #1:

101609-3530 as INJECTION-PUMP ASSEMBLY

Include in #2:

104258-5310 as _

Cross reference number

BOSCH 9 400 611 525 9400611525

ZEXEL 101609-3530 1016093530

KOMATSU 6221731230 6221731230

Zexel num

Bosch num

Firm num

Name

101609-3530

9 400 611 525

6221731230 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D108E 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 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 9.7

Pump speed r/min 1190 1190 1190

Average injection quantity mm3/st. 97.5 96.5 98.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 46 46

Boost pressure mmHg 345 345

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 10.5 9.3 11.7

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 E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 60 70

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 R1-1.1

Boost pressure kPa 16.7 14 19.4

Boost pressure mmHg 125 105 145

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position R1(9.7)

Boost pressure kPa 32.4 25.7 39.1

Boost pressure mmHg 245 195 295

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
----------
K=8
----------

Speed control lever angle

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

----------
a=11deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting (3)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=42.5deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(50deg)