101609-3080 ZEXEL 9 400 615 888 BOSCH INJECTION-PUMP ASSEMBLY 9400615888 1016093080 6221711220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 888 9400615888

ZEXEL 101609-3080 1016093080

KOMATSU 6221711220 6221711220

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Buy INJECTION-PUMP ASSEMBLY 101609-3080 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8570

3. GOVERNOR 105954-0160

4. SUPPLY PUMP 105210-5040

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5100

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 23.0{235}

13. NOZZLE-HOLDER 105048-3560

14. NOZZLE

105017-1120

15. NOZZLE SET

Include in #1:

101609-3080 as INJECTION-PUMP ASSEMBLY

Include in #2:

104242-8032 as _

Cross reference number

BOSCH 9 400 615 888 9400615888

ZEXEL 101609-3080 1016093080

KOMATSU 6221711220 6221711220

Zexel num

Bosch num

Firm num

Name

101609-3080

9 400 615 888

6221711220 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D108 K 14BF INJECTION PUMP ASSY PE6AD PE

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 131424-1520

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

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

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 3.6 3.55 3.65

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

Rack position (13.1)

Vist V 1.38 1.38 1.38

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 135.5 134.5 136.5

Max. variation between cylinders % 0 -2 2

Basic *

Injection quantity adjustment_02

Rack position (6.6)

Vist V 2.7 2.6 2.8

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 13.5 12.3 14.7

Max. variation between cylinders % 0 -10 10

Injection quantity adjustment_03

Remarks
Rack limit setting V = 0.9-0.04

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Vist = aa, (rack position = bb) (2)Rack position = cc
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aa=0.8V bb=16mm cc=1mm
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a=19deg+-5deg b=29deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
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a=(50deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Always use a wrench to hold the hex fitting on top of the master nozzle, when assembling or disassembling lines. If a wrench is not used, the master nozzle and manifold it is installed into may be damaged.
Check fuel line for "Close-in" Do NOT use fuel lines with an ID (inside diameter) LESS than 1.191 mm (0.0469 in). The fuel line ID can be checked using a 1.2 mm (.047 in) drill.If the drill bit can NOT be inserted into the fuel line high pressure hole, either drill out the line using a 1.6 mm (.063 in) drill or replace the fuel line with a new line. Use the same length and internal diameter lines each time the reference pump is tested.
If the fuel lines are not completely and thoroughly cleaned out after the drilling procedure, metal particles or foreign debris in the line will damage the master nozzles and contaminate the calibration fluid in the test stand.
After the hole has been drilled to the correct size, clean the line with solvent and remove any metal particles. Blow compressed air through the lines, after cleaning, to remove any solvent.
When using pressure air, wear a protective face shield and protective clothing. The maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.
9. Identify fuel lines and nozzles in the same order as the reference pump plunger and barrels (1-6 or 1-12) and use the same lines and nozzles each time the reference pump is run on the test bench.10. Select two test points (speeds and shot settings) that will cover the delivery range realized in a dealer's shop.Always set up the test points using only the pump rack zero pin. Do not set the rack full load or idle stops.11. The test stand and reference pump should be run for ten minutes.Make sure test stand pressures and temperatures are within published specifications and that they are stable.12. Set the first test point.Take five samples (draws) and record the individual pump and barrel deliveries for each sample (draw).13. Examine pump and barrel sample data:* Are the samples consistent?The MAXIMUM allowable difference between the HIGH and LOW delivery pump and barrel in the reference pump should be three cc's.If there is NOT a three cc difference, swap pump and barrels in the pump housing (or check master nozzles for damage) and re-test UNTIL the maximum HIGH to LOW