103682-0542 ZEXEL 9 400 613 107 BOSCH INJECTION-PUMP ASSEMBLY 9400613107 1036820542 6162732740

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 107 9400613107

ZEXEL 103682-0542 1036820542

KOMATSU 6162732740 6162732740

Service parts 103682-0542 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103068-1200

3. GOVERNOR 105445-1051

4. SUPPLY PUMP 105235-1870

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0490

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4951

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 31.4{320}

13. NOZZLE-HOLDER 105041-7102

14. NOZZLE 105025-3020

15. NOZZLE SET

Include in #1:

103682-0542 as INJECTION-PUMP ASSEMBLY

106873-2990 as _

Cross reference number

BOSCH 9 400 613 107 9400613107

ZEXEL 103682-0542 1036820542

KOMATSU 6162732740 6162732740

Zexel num

Bosch num

Firm num

Name

103682-0542
103682-0543

9 400 613 107

6162732740 KOMATSU

INJECTION-PUMP ASSEMBLY
6M170A * K 14BS PE4-8Z PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8130

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 131425-1620

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)
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 20.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 701 695 707

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 92 92

Boost pressure mmHg 690 690

Injection quantity adjustment_02

Adjusting point B

Rack position 9.7+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 56.5 50.5 62.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-4.4

Boost pressure kPa 24 21.3 26.7

Boost pressure mmHg 180 160 200

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(20.5)

Boost pressure kPa 78.6 71.9 85.3

Boost pressure mmHg 590 540 640

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: RAL (4)Boost compensator stroke: BCL (5)Idle sub spring setting: L1.
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K=17 RAL=21+0.2mm BCL=4.4+-0.1mm L1=5-0.5mm
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Speed control lever angle

F:Full speed I:Idle (1)Using base lever
----------

----------
a=20.5deg+-5deg b=33deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Clearance between stopper bolt and lever must be aa. (2)Use the hole at R = bb (3)- (4)No return spring
----------
aa=2+1mm bb=40mm
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a=16deg+-5deg b=40deg+-5deg