101692-3851 ZEXEL 9 400 616 054 BOSCH INJECTION-PUMP ASSEMBLY 9400616054 1016923851 6209721260

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 054 9400616054

ZEXEL 101692-3851 1016923851

KOMATSU 6209721260 6209721260

Service parts 101692-3851 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-9370

3. GOVERNOR 105401-0341

4. SUPPLY PUMP 105220-5280

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4890

11. Nozzle and Holder 6209-11-3100

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-0880

15. NOZZLE SET

Include in #1:

101603-6160 as _

101603-6161

101692-3851 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 054 9400616054

ZEXEL 101692-3851 1016923851

KOMATSU 6209721260 6209721260

Zexel num

Bosch num

Firm num

Name

101692-3851
101695-3530

9 400 616 054

6209721260 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D95L 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 131424-7420

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 3.2 3.15 3.25

Rack position
Point A 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 1100 1100 1100

Average injection quantity mm3/st. 75.8 74.8 76.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_02

Adjusting point -

Rack position 8.3+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 12.5 11.5 13.5

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.

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position 9.5

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 10.8

Boost pressure kPa 24 20 28

Boost pressure mmHg 180 150 210

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Boost compensator stroke (4)Rack difference from N = N1
----------
K=12 RAL=15+0.2mm N1=1100r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=80mm
----------
a=19deg+-3deg b=32deg+-3deg c=33deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

----------
a=58deg+-3deg b=2deg+-30min