101609-3091 ZEXEL 9 400 611 445 BOSCH INJECTION-PUMP ASSEMBLY 9400611445 1016093091 6221711210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 445 9400611445

ZEXEL 101609-3091 1016093091

KOMATSU 6221711210 6221711210

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Buy INJECTION-PUMP ASSEMBLY 101609-3091 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8570

3. GOVERNOR 105411-1641

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:

101609-3091 as INJECTION-PUMP ASSEMBLY

106671-4603 as _

Cross reference number

BOSCH 9 400 611 445 9400611445

ZEXEL 101609-3091 1016093091

KOMATSU 6221711210 6221711210

Zexel num

Bosch num

Firm num

Name

101609-3091

9 400 611 445

6221711210 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

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

Adjusting point A

Rack position 10.2

Pump speed r/min 1190 1190 1190

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 50.7 50.7

Boost pressure mmHg 380 380

Injection quantity adjustment_02

Adjusting point B

Rack position 6.3+-0.5

Pump speed r/min 405 405 405

Average injection quantity mm3/st. 12.5 11.3 13.7

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position 15+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 200 190 210

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 750 750 750

Rack position 10.05

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position 10.7

Boost pressure kPa 37.3 30.6 44

Boost pressure mmHg 280 230 330

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Rack difference between N = N3 and N = N4
----------
K=13 RAL=15+0.2mm N1=1190r/min N2=800r/min N3=1190r/min N4=350r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(15deg)+-5deg b=(31deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed = aa and rack position = bb, set the stopper bolt (to be sealed at delivery).
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)

Timing setting

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

----------
a=(50deg)

Information:

An additional 5 hours is allowed if the harness must replaced.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-4000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job for Group 2
An additional 10 hours is allowed if the harness must replaced.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group Number 1
Injector Harness Inspection
-Raise the engine enclosure hood.
-Remove the air intake pipe connecting the air filter to the turbo inlet.
-Remove the valve covers.
-Inspect the injector harness wiring for contact between the harness and valve springs.
Image1.1.1
Repair
-If the harness is close to the valve spring, adjust the harness by disconnecting the injector connector rotating the connector 360 degrees and reconnecting it. This should slightly twist the wires and pull them away from the springs.
Image1.2.1
Injector Harness Replacement (If Necessary)
-If the injector harness has contacted the spring and cut the wire or exposed the wire, then replace the injector harness that is under the valve cover.
-When installing the new harness to the valve cover base make sure the tabs do not turn while torquing down the bolts(see the picture below). Keep the tabs straight, and this will help keep the wiring away from the valve springs.
Image1.3.1
Group Number 2
Injector Harness Inspection
-Remove the rear engine enclosure.
-Remove the clamp for flex boot on the air filter housing.
-Remove the rubber elbow on the inlet of the compressor side of the turbocharger.
-Remove the clamps called out in the photo for the turbocharger outlet pipe that connects to the aftercooler.
Image2.1.1
-Remove all three engine valve covers.
-Inspect the injector harness wiring for contact between the harness and valve springs.
Image2.2.1
Repair
-If the harness is close to the valve spring, adjust the harness by disconnecting the injector connector rotating the connector 360 degrees and reconnecting it. This should slightly twist the wires and pull them away from the springs.
Image2.3.1
Injector Harness Replacement (If Necessary)
-If the injector harness has contacted the spring and cut the wire or exposed the wire, then replace the injector harness that is under the valve cover.
-Remove the doors, hood, Clean Emissions Module (CEM) and mounting plate, and valve cover base.
-When installing the new harness to the valve cover base make sure the tabs do not turn while torquing down the bolts(see the picture below). Keep the tabs straight, and this will help keep the wiring away from the valve springs.
Image2.4.1
-Reinstall the previously removed hardware, and use the new 344-8311 exhaust clamp.
Image2.5.1