103860-0031 ZEXEL 9 400 616 379 BOSCH INJECTION-PUMP ASSEMBLY 9400616379 1038600031 6164711510

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 379 9400616379

ZEXEL 103860-0031 1038600031

KOMATSU 6164711510 6164711510

Service parts 103860-0031 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103086-9071

3. GOVERNOR 105445-0632

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105649-0060

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4133

11. Nozzle and Holder 6162-12-3403

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

13. NOZZLE-HOLDER 105041-7112

14. NOZZLE 105015-6640

15. NOZZLE SET

Include in #1:

103860-0031 as INJECTION-PUMP ASSEMBLY

106873-7280 as _

Cross reference number

BOSCH 9 400 616 379 9400616379

ZEXEL 103860-0031 1038600031

KOMATSU 6164711510 6164711510

Zexel num

Bosch num

Firm num

Name

103860-0031
103860-0120

9 400 616 379

6164711510 KOMATSU

INJECTION-PUMP ASSEMBLY
SA8V170 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 131425-1920

Overflow valve opening pressure kPa 206 172 240

Overflow valve opening pressure kgf/cm2 2.1 1.75 2.45

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 1-3-4-5- 6-2-7-8

Pre-stroke mm 3.8 3.75 3.85

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-4 deg. 77 76.5 77.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-6 deg. 167 166.5 167.5

Difference between angles 5
Cyl.1-2 deg. 212 211.5 212.5

Difference between angles 6
Cal 1-7 deg. 269.5 269 270

Difference between angles 7
Cal 1-8 deg. 301.5 301 302

Injection quantity adjustment

Adjusting point A

Rack position 15.2

Pump speed r/min 1050 1050 1050

Each cylinder's injection qty mm3/st. 470 462.5 477.5

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_02

Adjusting point B

Rack position 7.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 60 55 65

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 13.3

Boost pressure kPa 26 25.3 26.7

Boost pressure mmHg 195 190 200

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 15.2

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Boost compensator stroke: BCL
----------
K=(15) RAL=15.7+0.2mm BCL=1.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(40deg)+-5deg b=(30deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = aa, speed = bb. (2)Clearance between stopper bolt and lever must be cc.
----------
aa=5mm bb=100r/min cc=2+1mm
----------
a=16deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of spline gear's aligning mark at No 1 cylinder's beginning of injection (key position) (3)B.T.D.C.: aa (4)-
----------
aa=36deg
----------
a=(130deg)