101609-3190 ZEXEL 9 400 610 774 BOSCH INJECTION-PUMP ASSEMBLY 9400610774 1016093190 6209721510

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 774 9400610774

ZEXEL 101609-3190 1016093190

KOMATSU 6209721510 6209721510

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Buy INJECTION-PUMP ASSEMBLY 101609-3190 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3190 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9721

3. GOVERNOR 105401-0660

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4890

11. Nozzle and Holder 6209-11-3100

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

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE

105017-0880

15. NOZZLE SET

Include in #1:

101609-3190 as INJECTION-PUMP ASSEMBLY

Include in #2:

104257-3031 as _

Cross reference number

BOSCH 9 400 610 774 9400610774

ZEXEL 101609-3190 1016093190

KOMATSU 6209721510 6209721510

Zexel num

Bosch num

Firm num

Name

101609-3190

9 400 610 774

6209721510 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D95L K 14BE INJECTION PUMP ASSY PE6A 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 131424-7420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure 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)
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 3.2 3.15 3.25

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 9.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 72 71 73

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 37.3 37.3

Boost pressure mmHg 280 280

Injection quantity adjustment_02

Adjusting point -

Rack position 7.3+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point E

Rack position 12.5+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 80 100

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 R1-0.8

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

Boost compensator adjustment_02

Pump speed r/min 750 750 750

Rack position R1(9.7)

Boost pressure kPa 26.7 22.7 30.7

Boost pressure mmHg 200 170 230

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: BCL
----------
K=14 RAL=12.5+0.2mm BCL=0.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=80mm
----------
a=28deg+-5deg b=14deg+-3deg c=32deg+-3deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

----------
a=58deg+-3deg b=2deg+-30min

Information:

(1) Thickness of spacer plate ... 9.970 0.025 mm (.3925 .0010 in.) Thickness of spacer plate gasket ... 0.208 0.025 mm (.0082 .0010 in.) For height of liner over top of spacer plate make reference to Cylinder Liner Projection.(2) Camshaft bearing bore (installed) ... 58.80 0.06 mm (2.315 .002 in.) Bore in block for camshaft bearings ... 65.100 0.025 mm (2.5630 .0010 in.)(3) Bore in block for main bearings (standard size) ... 96.926 0.013 mm (3.8160 .0005 in.) Bore in block for main bearings 0.51 mm (.020 in.) oversize ... 97.436 0.013 mm (3.8361 .0005 in.)(4) Dimension from center of main bearing bore to top of cylinder block (new) ... 383.515 0.165 mm (15.099 .0064 in.)(5) Dimension from center of main bearing bore to bottom of cylinder block (new) ... 153.99 0.10 mm (6.063 .004 in.)(6) Torque for bolts holding bearing caps for main bearings: a. Put 2P2506 Thread Lubricant on threads and washer face.b. Tighten all bolts to ... 41 4 N m (30 3 lb ft)c. Put a mark on each bolt and cap.d. Tighten all bolts from mark ... 90 5° Install bearing caps with the part number toward the front of the engine. Be sure that the mark (number) on the bearing cap next to the bolt hole is in agreement with the mark in the cylinder block.(7) Clearance between main bearing cap and cylinder block ... 0.033 mm (.0013 in.)tight to ... 0.043 mm (.0017 in.) loose Main bearing cap width ... 165.095 0.020 mm (6.4998 .0008 in.)Width of cylinder block for main bearing cap ... 165.100 0.018 mm (6.5000 .0007 in.) (8) Piston cooling orifice.
There are holes in the bores for the main bearings, between the cylinders for piston cooler orifices. These holes must have orifices (8) installed.
(9) Distance two dowels extend from the surface of the cylinder block ... 19.8 0.5 mm (.78 .02 in.)(10) Distance hollow dowel extends from the surface of the cylinder block ... 16.0 0.5 mm (.63 .02 in.)(11) Depth to install two dowels below the surface of the cylinder block (apply loctite #11358) ... 1.0 0.5 mm (.04 .02 in.)(12) Distance dowels extend from the front face of the cylinder block ... 22.4 0.5 mm (.88 .02 in.)(13) Distance stud extends from the front face of the cylinder block ... 15.7 0.5 mm (.62 .02 in.)(14) Distance two dowels extend from the rear face of the cylinder block ... 12.7 0.5 mm (.50 .02 in.)