103682-0420 ZEXEL 9 400 616 362 BOSCH INJECTION-PUMP ASSEMBLY 9400616362 1036820420 6162731652

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 362 9400616362

ZEXEL 103682-0420 1036820420

KOMATSU 6162731652 6162731652

Service parts 103682-0420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103068-1070

3. GOVERNOR 105445-0750

4. SUPPLY PUMP 105235-1870

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4232

11. Nozzle and Holder 6164-11-3101

12. Open Pre:MPa(Kqf/cm2) 29.4{300}

13. NOZZLE-HOLDER 105041-7101

14. NOZZLE 105015-7060

15. NOZZLE SET

Include in #1:

103682-0420 as INJECTION-PUMP ASSEMBLY

106873-2540 as _

Cross reference number

BOSCH 9 400 616 362 9400616362

ZEXEL 103682-0420 1036820420

KOMATSU 6162731652 6162731652

Zexel num

Bosch num

Firm num

Name

103682-0420
103682-0440

9 400 616 362

6162731652 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D160 K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

Bosch type code EFEP215A

Nozzle 105780-0050

Bosch type code DN6TD119NP1T

Nozzle holder 105780-2090

Bosch type code EFEP215

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500

Overflow valve (drive side) 131425-1620

Overflow valve opening pressure (drive side) kPa 255 221 289

Overflow valve opening pressure (drive side) kgf/cm2 2.6 2.25 2.95

Overflow valve (governor side) 131425-1620

Overflow valve opening pressure (governor side) kPa 255 221 289

Overflow valve opening pressure (governor side) 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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 15.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 535 530 540

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 58 53 63

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 16+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 390 390 430

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Deliver without the torque control spring operating. (3)RACK LIMIT: RAL
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K=9 RAL=16+0.2mm
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Speed control lever angle

F:Full speed I:Idle S:Stop
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a=(16deg)+-5deg b=(42deg)+-5deg c=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb. (2)Clearance between stopper bolt and lever must be cc.
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aa=100r/min bb=5mm cc=(0.8)mm
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a=40deg+-5deg b=24deg+-5deg

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A (B) branch piping Fuel inlet C (D) Overflow valve Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
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