103662-2851 ZEXEL 9 400 619 419 BOSCH INJECTION-PUMP ASSEMBLY 9400619419 1036622851 6166711410

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 419 9400619419

ZEXEL 103662-2851 1036622851

KOMATSU 6166711410 6166711410

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Buy INJECTION-PUMP ASSEMBLY 103662-2851 zexel genuine, new aftermarket engine parts with delivery

Service parts 103662-2851 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103066-9530

3. GOVERNOR 105445-0611

4. SUPPLY PUMP 105235-1801

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4133

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER 105041-7112

14. NOZZLE 105015-6640

15. NOZZLE SET

Include in #1:

101402-1021 as _

103662-2851 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 419 9400619419

ZEXEL 103662-2851 1036622851

KOMATSU 6166711410 6166711410

Zexel num

Bosch num

Firm num

Name

103662-2851
103662-2930

9 400 619 419

6166711410 KOMATSU

INJECTION-PUMP ASSEMBLY
SA12V170 * 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 1-5-3-6- 2-4

Pre-stroke mm 3.8 3.75 3.85

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 17.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 547 542 552

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Remarks
Standard point A's rack position same as 103664-1230 in row R

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 51.5 46.5 56.5

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Minimum - maximum speed specification (2)Variable speed specification: idling adjustment (3)Target notch: K (4)Idle sub spring setting: L1.
----------
K=(5) L1=6.5-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb. (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=37deg+-5deg b=12deg+-5deg c=12deg+-5deg

0000000901

F:Full load I:Idle S:Stop (1)The distance between the stopper bolt and the lever must be aa.
----------
aa=(0.8)mm
----------
a=40deg+-5deg b=25deg+-5deg c=(23deg)+-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=38deg
----------
a=(130deg)

Information:

1. Disconnect fuel line (3) from the fuel transfer pump. Cap or plug immediately.2. Disconnect fuel line (4) from the fuel transfer pump. Cap or plug immediately.3. Remove bolts (1).4. Remove fuel transfer pump (2). Check the condition of the O-ring seal on the fuel transfer pump. If necessary, make a replacement. Put clean engine oil on the O-ring seal when assembling fuel transfer pump. For installation of the fuel transfer pump, reverse the removal steps.Disassemble & Assemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove seal (1) from the fuel transfer pump.
Cover (2) is under spring tension. Remove the bolts that hold cover (2) slowly to prevent injury.
2. Remove bolts (3) and cover (2) the housing. 3. Remove seals (4) and valve (5) from cover (2). 4. Remove spring (6) from the piston.
Mark the orientation of valve (8) as to its location in the housing.
5. Remove washer (7) and valve (8) from the housing. 6. Remove piston (9) and sleeve (10) from the housing. 7. Remove seal (11) from sleeve (12). 8. Remove guide and tappet assembly (13) from the housing. 9. Remove seal (14) from guide (15).
If tappet (17) or guide (15) are damaged or worn, they must be replaced as a unit.
10. Remove ring (16) from tappet (17) and the tappet from guide (15). 11. Remove the bolts and cover (18) from the housing. 12. Remove seal (19) from cover (18). 13. Remove valve (20) from the housing. The following steps are for the assembly of the fuel transfer pump.14. Install valve (20) in the housing. Put clean fuel on seal (19) and install it on cover (18). Install the cover on the housing.15. Install tappet (17) in guide (15). Install ring (16) on tappet (17) to hold the tappet in the guide.16. Put clean fuel on seal (14) and install it on the guide and tappet assembly (13). Install guide and tappet assembly (13) in the housing.17. Put clean fuel on seal (11) and install it on sleeve (12). Install sleeve (12) in the housing.18. Install piston (9) in the housing. Install valve (8) and washer (7) in the housing. Install spring (6) in the piston.19. Install valve (5) in cover (2).20. Put clean fuel on seals (4) and put them in position on cover (2). Install cover (2) on the housing.21. Put seal (1) in position on the fuel transfer pump.End By:a. install fuel transfer pump