101605-3021 ZEXEL 9 400 612 338 BOSCH INJECTION-PUMP ASSEMBLY 9400612338 1016053021 6137721340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 338 9400612338

ZEXEL 101605-3021 1016053021

KOMATSU 6137721340 6137721340

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Buy INJECTION-PUMP ASSEMBLY 101605-3021 zexel genuine, new aftermarket engine parts with delivery

Service parts 101605-3021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2480

3. GOVERNOR 105410-7670

4. SUPPLY PUMP 105210-4560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0371

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5430

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-4480

14. NOZZLE

105015-5020

15. NOZZLE SET

Include in #1:

101401-4421 as _

101605-3021 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 338 9400612338

ZEXEL 101605-3021 1016053021

KOMATSU 6137721340 6137721340

Zexel num

Bosch num

Firm num

Name

101605-3021

9 400 612 338

6137721340 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D105 * 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 6-2-550

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 3.3 3.25 3.35

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 10.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 54.5 53.5 55.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 7 6 8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Rack difference between N = N1 and N = N2 (3)Rack difference between N = N3 and N = N4
----------
K=7 N1=1050r/min N2=300r/min N3=1050r/min N4=800r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=6deg+-5deg b=28deg+-5deg c=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=10deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(1deg)

Information:

Recommended Procedure With Chassis Dynamometer
Possible Causes/Corrections Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceDo a Power Analysis Report (PAR), Level II, to check engine performance. See Special Instruction, Form No. SEHS8025 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Make the necessary adjustments or repairs to the engine if needed.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.Recommended Procedure Without Chassis Dynamometer
Possible Causes/Corrections Minor Operating FaultsTo help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the "Primary Engine Checks" section. Fuel Ratio Control Out Of Adjustment Or DefectiveFollow the procedure in the Testing and Adjusting Section of this Service Manual. Fuel Injection Timing Not CorrectFollow the procedures in the Testing and Adjusting Section of this Service Manual. Check Engine PerformanceInstall the tooling and follow the procedure given in the Road Test section.At this point, the governor fuel settings should be verified. See the Testing and Adjusting Section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see "Owner/Operator Input" section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.