101609-3630 ZEXEL 9 400 615 912 BOSCH INJECTION-PUMP ASSEMBLY 9400615912 1016093630 3864090

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 912 9400615912

ZEXEL 101609-3630 1016093630

KOMATSU 3864090 3864090

Include in #2:

104266-1150 as _

Cross reference number

BOSCH 9 400 615 912 9400615912

ZEXEL 101609-3630 1016093630

KOMATSU 3864090 3864090

Zexel num

Bosch num

Firm num

Name

101609-3630

9 400 615 912

3864090 KOMATSU

INJECTION-PUMP ASSEMBLY
6D102E K

101609-3630

9 400 615 912

6734711340 KOMATSU

INJECTION-PUMP ASSEMBLY
6D102E 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 9.4

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 52 51 53

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.7+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position 9.6++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 55 55 65

Fixing the lever *

Rack limit *

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)The torque control spring must does not have a set force. (5)Adjust the secondary timing before adjusting the governor.
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K=8
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=9deg+-5deg b=23deg+-5deg

Stop lever angle

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