103682-0420 ZEXEL 9 400 616 362 BOSCH INJECTION-PUMP ASSEMBLY 9400616362 1036820420 6162731652

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 362 9400616362

ZEXEL 103682-0420 1036820420

KOMATSU 6162731652 6162731652

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Buy INJECTION-PUMP ASSEMBLY 103682-0420 zexel genuine, new aftermarket engine parts with delivery

Service parts 103682-0420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 103068-1070

3. GOVERNOR 105445-0750

4. SUPPLY PUMP 105235-1870

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4232

11. Nozzle and Holder 6164-11-3101

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

13. NOZZLE-HOLDER 105041-7101

14. NOZZLE 105015-7060

15. NOZZLE SET

Include in #1:

103682-0420 as INJECTION-PUMP ASSEMBLY

106873-2540 as _

Cross reference number

BOSCH 9 400 616 362 9400616362

ZEXEL 103682-0420 1036820420

KOMATSU 6162731652 6162731652

Zexel num

Bosch num

Firm num

Name

103682-0420
103682-0440

9 400 616 362

6162731652 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D160 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 (drive side) 131425-1620

Overflow valve opening pressure (drive side) kPa 255 221 289

Overflow valve opening pressure (drive side) kgf/cm2 2.6 2.25 2.95

Overflow valve (governor side) 131425-1620

Overflow valve opening pressure (governor side) kPa 255 221 289

Overflow valve opening pressure (governor side) 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 15.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 535 530 540

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 58 53 63

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 16+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 390 390 430

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Deliver without the torque control spring operating. (3)RACK LIMIT: RAL
----------
K=9 RAL=16+0.2mm
----------

Speed control lever angle

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

----------
a=(16deg)+-5deg b=(42deg)+-5deg c=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb. (2)Clearance between stopper bolt and lever must be cc.
----------
aa=100r/min bb=5mm cc=(0.8)mm
----------
a=40deg+-5deg b=24deg+-5deg

0000001501 Q ADJUSTMENT PIPING

Tester fuel pipe A (B) branch piping Fuel inlet C (D) Overflow valve Piping at standard injection quantity adjustment 1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
----------

----------

Timing setting

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

----------
a=(70deg)

Information:

Test 1 - Overspeed Switch (OS)
Table 1
Overspeed Switch (OS)
Step Engine RPM Action Correct Result
A 25 + 5 rpm less than 75% Overspeed Verify rpm Press the 75% Verify button No engine shutdown
B 25 + 5 rpm more than 75% Overspeed Verify rpm Press the 75% Verify button Air and fuel shutoff
C Manually reset the air shutoff lever at the top of the air inlet, if equipped. Press the ESS reset button. Test 2 - Emergency Stop Switch (ES)
Table 2
Emergency Stop Switch (ES)
Step Engine RPM Action Correct Result
A Any rpm above the crank terminate rpm Press the push button for the emergency stop switch Air and fuel shutoff
B Manually reset the air shutoff lever at the top of the air inlet, if equipped. Turn ES switch in the dirction that is shown on the face of the push button in order to reset the switch. Test 3 - Normal Stop Switch (NSS)
Table 3
Normal Stop Switch (NSS)
Step Engine RPM Action Correct Result
A Any rpm above the crank terminate rpm Push the normal stop switch (NSS) Fuel shutoff Test 4 - Water Temperature Contactor Switch
Table 4
Water Temperature Contactor Switch (WTS)
Step Engine RPM Action Correct Result
A Any rpm above the crank terminate rpm Place a jumper across terminals TS-2 and TS-7. Fuel shutoff
B Remove the jumper from terminals TS-2 and TS-7. Test 5 - Oil Pressure Switch (OPS1)
Table 5
Oil Pressure Switch (OPS1)
Step Engine RPM Action Correct Result
A Any rpm above the crank terminate rpm Place a jumper across terminals OPS1-1 and OPS1-3. Fuel shutoff
B Remove the jumper from terminals OPS1-1 and OPS1-3. Test 6 - Oil Pressure Switch (OPS2)
Table 6
Oil Pressure Switch (OPS2)
Step Engine RPM Action Correct Result
A 25 + 5 rpm less than the setting for the oil step speed Place a jumper across terminals OPS2-1 and OPS2-3. No engine shutdown.
B 25 + 5 rpm more than the setting for the oil step speed Place a jumper across terminals OPS2-1 and OPS2-3. Fuel shutoff 9 seconds after the oil step speed is reached.
C Remove the jumper from across terminals OPS2-1 and OPS2-3.