101609-3660 ZEXEL F 01G 0V0 003 BOSCH INJECTION-PUMP ASSEMBLY f01g0v0003 1016093660 3939727

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 0V0 003 f01g0v0003

ZEXEL 101609-3660 1016093660

KOMATSU 3939727 3939727

Service parts 101609-3660 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

101062-9310

3. GOVERNOR 105404-5900

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105158-5002

11. Nozzle and Holder 4063212

12. Open Pre:MPa(Kqf/cm2) 22.0{224}

13. NOZZLE-HOLDER 105088-2002

14. NOZZLE

105017-2910

15. NOZZLE SET

Include in #1:

101609-3660 as INJECTION-PUMP ASSEMBLY

Include in #2:

104214-0160 as _

Cross reference number

BOSCH F 01G 0V0 003 f01g0v0003

ZEXEL 101609-3660 1016093660

KOMATSU 3939727 3939727

Zexel num

Bosch num

Firm num

Name

101609-3660

F 01G 0V0 003

3939727 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102E K 14BE INJECTION PUMP ASSY PE6A PE

101609-3660

F 01G 0V0 003

6738711140 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102E K 14BE INJECTION PUMP ASSY PE6A 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 131424-3420

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 2.6 2.55 2.65

Rack position
After adjusting injection quantity. R=A

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 10.7

Pump speed r/min 975 975 975

Average injection quantity mm3/st. 123.5 122.5 124.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 9.5 8.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point D

Rack position 10.9++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 90 100

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Rack limit *

Boost compensator adjustment

Pump speed r/min 850 850 850

Rack position 9.3

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Boost compensator adjustment_02

Pump speed r/min 850 850 850

Rack position R1-1

Boost pressure kPa 32 30.7 33.3

Boost pressure mmHg 240 230 250

Boost compensator adjustment_03

Pump speed r/min 850 850 850

Rack position R1(10.7)

Boost pressure kPa 53.3 53.3 53.3

Boost pressure mmHg 400 400 400

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)It is not necessary to supply hydraulic pressure because the specification is for the hydraulic ACT normally ON. (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=17 BCL=(1.4)mm N1=975r/min N2=500r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=77mm
----------
a=11deg+-5deg b=31deg+-3deg c=35deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
----------
T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
----------

0000001601 I/P WITH LOAD PLUNGER ADJ

Adjusting procedure for load plunger equipped pump with RSV (cam lock) governor (see service information S.I. 434 for details). At cam lift h+-0.01, set the camshaft c deg from the * mark in accordance with the timing adjustment procedure. 2. Align the flyweight's timing tooth position and the lock pin groove and then fully tighten the flyweight to the camshaft. Then, remove the lock pin. 3. Adjust the maximum variation between cylinders and injection quantity. 4. Adjust using the pre-stroke adjusting shim so that the pre-stroke value is the value for 4/4 load (standard point A). 5. After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation between cylinders are as specified. 6. At delivery, again fix the flyweight using the lock pin.
----------
h=2.6mm c=5deg+-30min
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Timing setting

(1)Pump vertical direction (2)Key groove position for No. 1 cylinder's cam lift h = cc (at BTDC aa). (3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity adjustment). (4)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). (5)B.T.D.C.: aa
----------
aa=10deg bb=0deg cc=2.6+-0.01mm
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a=55deg18min+-3deg b=55deg18min+-3deg13min48sec c=5deg+-30min