101602-3460 ZEXEL F 019 Z10 012 BOSCH INJECTION-PUMP ASSEMBLY f019z10012 1016023460 6136721310

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 012 f019z10012

ZEXEL 101602-3460 1016023460

KOMATSU 6136721310 6136721310

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Buy INJECTION-PUMP ASSEMBLY 101602-3460 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-3460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2470

3. GOVERNOR 105410-6930

4. SUPPLY PUMP 105210-4560

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0371

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5420

11. Nozzle and Holder 6136-12-3100

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

13. NOZZLE-HOLDER 105031-4480

14. NOZZLE 105015-5010

15. NOZZLE SET

Include in #1:

101402-4550 as _

101602-3460 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 012 f019z10012

ZEXEL 101602-3460 1016023460

KOMATSU 6136721310 6136721310

Zexel num

Bosch num

Firm num

Name

101602-3460

F 019 Z10 012

6136721310 KOMATSU

INJECTION-PUMP ASSEMBLY
6D105 * 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

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 10.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 56.5 55.5 57.5

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. 8 7 9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

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=9 N1=1075r/min N2=800r/min N3=1075r/min N4=500r/min
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=28deg+-5deg c=32deg+-3deg

Information:

Illustration 2 g06542023
(T1a) Eccentric gasket
Install adjustment tool (T1) on the injector for center cylinder (2) using eccentric gasket (T1a). Install eccentric gasket (T1a) over the check valve in place of the O-ring.
Illustration 3 g06542029
(T1b) Supply fitting
(T1c) Purge hose
(T2) Inlet hose
Connect a suitable container filled with clean diesel fuel to supply fitting (T1b) using inlet hose (T2). Place a small cup under purge hose (T1c).
Illustration 4 g06536094
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Rotate the engine in the direction of rotation (clockwise) until center cylinder (2) is at Top-Dead-Center (TDC) with the compression stroke. The reference mark for center cylinder (2) must be aligned with the TDC index mark (A) and the valves must be closed.
Illustration 5 g06536129
Center cylinder (2) at 11° Before-Top-Dead-Center (BTDC)
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Illustration 6 g06542031
(T1c) Purge hose
Raise the fuel container above the level of the injector. Rotate the engine counterclockwise until reference mark (2) is to the left of the 11° Before-Top-Dead-Center (BTDC) mark or until fuel is observed flowing from purge hose (T1c).
Illustration 7 g06542019
(T1c) Purge hose
Rotate the engine clockwise and stop immediately when the fuel stops flowing from purge hose (T1c). The beginning of injection has been reached when the fuel stops flowing.
Illustration 8 g06536129
Center cylinder (2) rotated 11°
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Observe the alignment of the reference mark for center cylinder (2) and the 11° BTDC mark.Note: If mark (2) aligns with the 11° mark, timing is correct and proceed to Step 9. If marks are not aligned, the injector timing must be adjusted. Adjust injector timing using the procedure in Step 8.
Observe the position of the reference mark for center cylinder (2) and the mark at 11° of rotation for BTDC. Note if the injector timing is early or late.Note: If the reference mark for center cylinder (2) is left of the 11° BTDC mark, injector timing is early. If the mark is to the right, injector timing is late.
Illustration 9 g06536148
(B) Jam nut
Rotate the engine to align the reference mark for center cylinder (2) and the 11° BTDC mark. Loosen jam nut (B) on the fuel injector timing adjustment screw. For late timing, proceed to Step 8b. For early timing, proceed to Step 8c
Illustration 10 g06536146
(C) Adjustment screw
Late Timing: While watching purge hose (T1c), turn adjustment screw (C) clockwise until fuel flow stops.
Early Timing: While watching purge hose (T1c), turn adjustment screw (C) counterclockwise until fuel flow starts. Then, turn adjustment screw (C) clockwise until fuel flow stops.
Hold adjustment screw (C) and tighten jam nut (B) securely. Check the injector timing by repeating Steps 5 through 7.
Remove adjustment tool (T1) and install with eccentric gasket (T1a) on the injector for drive clutch side cylinder (1). Rotate the engine 120° clockwise using the reference mark for cylinder (1). Repeat Steps 4 through 8.
Repeat Step 9 for alternator side cylinder (3).
Illustration 11 g06543249
(1) 562-0435 O-Ring Seal
Remove adjustment tool (T1) and eccentric gasket (T1a). Reinstall the fuel rail with four new