101609-3831 ZEXEL F 01G 000 00D BOSCH INJECTION-PUMP ASSEMBLY f01g00000d 1016093831 3864383

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 000 00D f01g00000d

ZEXEL 101609-3831 1016093831

KOMATSU 3864383 3864383

Service parts 101609-3831 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

101062-9310

3. GOVERNOR 105404-6190

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105158-5140

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 25.0(255)

13. NOZZLE-HOLDER 105088-2010

14. NOZZLE 105017-3610

15. NOZZLE SET

Include in #1:

101609-3831 as INJECTION-PUMP ASSEMBLY

Include in #2:

104268-1300 as _

Cross reference number

BOSCH F 01G 000 00D f01g00000d

ZEXEL 101609-3831 1016093831

KOMATSU 3864383 3864383

Zexel num

Bosch num

Firm num

Name

101609-3831

F 01G 000 00D

3864383 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102 K 14BE INJECTION PUMP ASSY PE6A PE

101609-3831

F 01G 000 00D

6738711620 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102 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 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 125 124 126

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Boost pressure kPa 77.3 77.3

Boost pressure mmHg 580 580

Injection quantity adjustment_02

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13 12 14

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 9.75+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 50 45 55

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point F

Rack position 13.1++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 135 145

Fixing the lever *

Boost pressure kPa 107 107

Boost pressure mmHg 800 800

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1(9.75)

Boost pressure kPa 30.7 28 33.4

Boost pressure mmHg 230 210 250

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1+0.75

Boost pressure kPa 42.7 40 45.4

Boost pressure mmHg 320 300 340

Boost compensator adjustment_03

Pump speed r/min 650 650 650

Rack position (11.3)

Boost pressure kPa 64 64 64

Boost pressure mmHg 480 480 480

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)Stop lever at stopping (with the speed lever at full) (6)Boost compensator stroke: BCL (7)Idle sub spring setting: L1.
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K=6 BCL=(1.55)mm L1=6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)When pump speed set at bb (3)Stopper bolt setting
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aa=900r/min bb=750r/min
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a=5deg+-5deg b=22deg+-5deg c=7deg+-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

0000001501 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.
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h=2.6+-0.01mm c=6deg12min+-30min
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Timing setting

(1)Pump vertical direction (2)Key groove position for No. 1 cylinder's cam lift h = dd (at BTDC bb). (3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity adjustment). (4)B.T.D.C.: position for No. 1 cylinder's key groove position for cc (at this position, fix the governor flyweight using the lockpin at delivery). (5)B.T.D.C: aa (B.T.D.C: bb at 0 boost rack)
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aa=12.4deg bb=13deg cc=0deg dd=2.6+-0.01mm
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a=55deg18min+-3deg b=55deg18min+-3deg13min48sec c=6deg12min+-30min