101609-3120 ZEXEL 9 400 615 890 BOSCH INJECTION-PUMP ASSEMBLY 9400615890 1016093120 6221711270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 890 9400615890

ZEXEL 101609-3120 1016093120

KOMATSU 6221711270 6221711270

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Buy INJECTION-PUMP ASSEMBLY 101609-3120 zexel genuine, new aftermarket engine parts with delivery

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104257-3013 as _

Cross reference number

BOSCH 9 400 615 890 9400615890

ZEXEL 101609-3120 1016093120

KOMATSU 6221711270 6221711270

Zexel num

Bosch num

Firm num

Name

101609-3120

9 400 615 890

6221711270 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D108 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

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 9.1

Boost pressure kPa 4 1.3 6.7

Boost pressure mmHg 30 10 50

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
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K=13 RAL=15+0.2mm N1=1190r/min N2=800r/min N3=1190r/min N4=350r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=18deg+-5deg b=31deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Stopper bolt setting
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aa=0r/min bb=1-0.2mm
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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)-
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a=(50deg)

Information:

Camshaft
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013 mm) and the minimum diameter worn is 2.4970 in. (63.424 mm).To find lobe lift (A) of camshaft, use the following procedure:1. Measure lobe height (B) of one exhaust and one intake lobe.2. Measure base circle (C) of one exhaust and one intake lobe.3. Subtract base circle (C) dimension (STEP 2) from lobe height (B) dimension (STEP 1). The difference is actual lobe lift (A).4. The specified (new) lobe lift (A) is: (a) Exhaust lobe ... .3071 in.(7.800 mm)(b) Intake lobe ... .3077 in.(7.816 mm)5. The maximum permissible difference between actual lobe lift (STEP 3) and specified lobe lift (STEP 4) is .025 in. (0.64 mm).
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1. Heat the gear to a temperature of approximately 400°F (204°C) before installing on the camshaft.
Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600°F (315°C). Heating the gear with a torch or to a temperature of more than 600°F (315°C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completly seated against the shoulder of the camshaft.
Do not drive the gear on the camshaft.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (3) in washer with hole (4) in camshaft and install washer (2).5. Install screw (1) and