101692-3830 ZEXEL 9 400 616 052 BOSCH INJECTION-PUMP ASSEMBLY 9400616052 1016923830 6209711230


 

Information injection-pump assembly

BOSCH 9 400 616 052 9400616052
ZEXEL 101692-3830 1016923830
KOMATSU 6209711230 6209711230
101692-3830 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 616 052 9400616052
ZEXEL 101692-3830 1016923830
KOMATSU 6209711230 6209711230


Zexel num
Bosch num
Firm num
Name
101692-3830 
9 400 616 052 
6209711230  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   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   10.9
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   78.2 77.2 79.2
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   8.2+-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   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101692-3830
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference from N = N1 (4)Rack difference between N = N2 and N = N3
----------
K=13 RAL=15+0.2mm N1=1100r/min N2=1100r/min N3=450r/min
----------

Speed control lever angle

Test data 101692-3830
F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=80mm
----------
a=34deg+-5deg b=18deg+-3deg c=32deg+-3deg

Stop lever angle

Test data 101692-3830
N:Pump normal S:Stop the pump.
----------

----------
a=1deg+-5deg b=53deg+-5deg

Timing setting

Test data 101692-3830
(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




Information:


When using an external electrical source to start your engine: turn the START switch off, remove the key, and turn off all electrical accessories before attaching cables.When using jumper cables always connect the POSITIVE (+) cable to the POSITIVE (+) terminal of the battery connected to the starter solenoid. Connect the NEGATIVE (-) cable from the external source to the starter NEGATIVE (-) terminal. If not equipped with a starter NEGATIVE terminal, connect to the engine block.Do not reverse the battery cables. The alternator can be damaged. Attach the ground cable last and remove first.
1. Connect one end of the cable to the POSITIVE (+) terminal of the battery being started. Connect the other end to the POSITIVE (+) terminal of the power source.2. Connect one end of the other cable to the NEGATIVE (-) terminal of the power source. Connect the other end to the starter NEGATIVE (-) terminal or to the engine block. This prevents potential sparks from igniting combustible gases produced by some batteries.3. Start the engine.4. After the engine starts, disconnect the cable from the starter NEGATIVE (-) terminal or engine block. Disconnect the other end from the NEGATIVE (-) terminal of the power source.5. Disconnect the cable from the POSITIVE (+) terminal of the battery on the engine being started. Disconnect the cable from the POSITIVE (+) terminal of the power source.Glow Plugs
Precombustion Chamber Engines
Never use the glow plugs when the engine is warm and running.
HEAT/START switch: HEAT (1), OFF (2), and START (3) positions.1. Push the HEAT/START switch and turn the switch to the HEAT position. Maintain the switch in the HEAT position for the appropriate time shown in the Starting Aid Chart.2. Turn the HEAT/START switch to the START position.3. If the engine runs rough after starting, turn the HEAT/START switch to the HEAT position. Maintain the position until the engine runs smoothly. Air Starting
For good life of the air starting motor, the air supply must be free of dirt and water. A lubricator must be used with the starting system. Use non detergent 10W engine oil for temperatures above 0°C (32°F). Use air tool oil for temperatures below 0°C (32°F).Older air starters are equipped with a lubricator bowl. Newer air starters are self-lubricating.1. Open and close the drain valve on the bottom of the air tank to drain condensation and oil carryover.2. Check the air supply pressure. The air starting motor requires a minimum of 690 kPa (100 psi) air pressure. The maximum air pressure must not exceed 1034 kPa (150 psi).
Air starter: air valve (1) and lubricator bowl (2)3. Check the oil level in the lubricator bowl (if equipped, 2). Keep the bowl at least half full and add lubricant if necessary.4. Push the air valve (1) or the engine start button to crank the engine. Release the valve or button as soon as the engine starts.Cold Weather Starting Aids
Personal injury or death can result from using ether.Personal injury or property damage can result from alcohol or starting fluids.

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Group cross 101692-3830 ZEXEL

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