101609-3542 ZEXEL 9 400 612 000 BOSCH INJECTION-PUMP ASSEMBLY 9400612000 1016093542 3863886

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 000 9400612000

ZEXEL 101609-3542 1016093542

KOMATSU 3863886 3863886

Service parts 101609-3542 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9050

3. GOVERNOR 105404-5680

4. SUPPLY PUMP

105220-5960

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:

101609-3542 as INJECTION-PUMP ASSEMBLY

Include in #2:

104266-1120 as _

Cross reference number

BOSCH 9 400 612 000 9400612000

ZEXEL 101609-3542 1016093542

KOMATSU 3863886 3863886

Zexel num

Bosch num

Firm num

Name

101609-3542

9 400 612 000

3863886 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D102E K

101609-3542

9 400 612 000

6736711170 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D102E 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 9.6

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 93 92 94

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 12 11 13

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. 85 85 95

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 700 700 700

Rack position 9.15

Boost pressure kPa 18.7 16 21.4

Boost pressure mmHg 140 120 160

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 10.2

Boost pressure kPa 40 33.3 46.7

Boost pressure mmHg 300 250 350

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (When hydraulic cylinder is OFF) (5)Boost compensator stroke: BCL (6)When hydraulic cylinder ON: P1 (7)Rack difference between N = N1 and N = N2
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K=8 BCL=1.05+-0.1mm P1=((392)kPa{(4)kgf/cm2}) N1=1175r/min N2=700r/min
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Speed control lever angle

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

----------
a=8deg+-5deg b=30deg+-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=19.5deg bb=0deg
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a=54deg54min+-3deg b=9deg45min+-30min