Information injection-pump assembly
BOSCH
9 400 615 897
9400615897
ZEXEL
101609-3301
1016093301
KOMATSU
3863452
3863452
Rating:
Service parts 101609-3301 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101609-3301
as INJECTION-PUMP ASSEMBLY
Include in #2:
104257-1090
as _
Cross reference number
BOSCH
9 400 615 897
9400615897
ZEXEL
101609-3301
1016093301
KOMATSU
3863452
3863452
Zexel num
Bosch num
Firm num
Name
101609-3301
9 400 615 897
3863452 KOMATSU
INJECTION-PUMP ASSEMBLY
6BT-C K
6BT-C K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-3420
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.5
2.45
2.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.9
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
81
80
82
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
42.7
42.7
Boost pressure
mmHg
320
320
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.4+-0.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
15
14
16
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder ON
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
80
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder OFF
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
750
750
750
Rack position
R1-0.5
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
Boost compensator adjustment_02
Pump speed
r/min
750
750
750
Rack position
R1(8.9)
Boost pressure
kPa
29.3
22.6
36
Boost pressure
mmHg
220
170
270
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)The torque control spring does not operate.
(4)Adjust the secondary timing before adjusting the governor.
(5)RACK LIMIT (When hydraulic cylinder is OFF)
(6)Set idle sub-spring
(7)Main spring setting
(8)Boost compensator stroke: BCL
(9)When hydraulic cylinder ON: P1
----------
K=10 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
----------
K=10 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)At hole at R = aa (center)
----------
aa=80mm
----------
a=36deg+-3deg b=20deg+-5deg
----------
aa=80mm
----------
a=36deg+-3deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=18deg bb=0deg
----------
a=54deg54min+-3deg b=9deg+-30min
----------
aa=18deg bb=0deg
----------
a=54deg54min+-3deg b=9deg+-30min
Information:
New cylinder blocks have been introduced on the 4.236 engine for the Backhoe Loaders. They have a larger cylinder liner parent bore diameter. The outside diameter of the cylinder liner is also larger. There is no longer a flame ring on the liner. The change became effective with engine serial number LD70178U106654N. The engine serial number is located above the fuel injection pump on the block.(1) Outside diameter of cylinder liner. Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed) ... 0.20 mm (.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( .001 in)Length of cylinder liner ... 227.10 to 227.43 mm (8.941 to 8.954 in)(3) Liner (flange) projection [do not measure from flame ring (if so equipped)] ... 0.10 mm (.004 in) above to ... 0.10 mm (.004 in) below Flange thickness of cylinder liner ... 3.81 to 3.86 mm (.150 to .152 in)Flange projection ... 0.10 mm (.004 in) above to ... 0.10 mm (.004 in) below face of cylinder block(4) Diameter of parent bore in cylinder block for liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (.150 to .154 in)(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ... 55.563 to 55.593 mm (2.1875 to 2.1887 in) Diameter of bearing bore for camshaft ... 50.800 to 50.843 mm (2.0000 to 2.0017 in)Diameter of bore for No. 2 journal ... 50.55 to 50.592 mm (1.990 to 1.9918 in)Diameter of bore for No. 3 journal ... 50.04 to 50.084 mm (1.970 to 1.9718 in)Clearance of camshaft in bore:Front (No. 1) ... 0.064 to 0.114 mm (.0025 to .0045 in)No. 2, No. 3 ... 0.064 to 0.135 mm (.0025 to .0053 in)Camshaft end play ... 0.10 to 0.41 mm (.004 to .016 in)Maximum permissible end play (worn) ... 0.51 mm (.020 in)(7) Diameter of bores in cylinder block for main bearings ... 80.42 to 80.44 mm (3.166 to 3.167 in)(8) Torque for main bearing cap bolts ... 245 N m (180 lb ft).Total height of cylinder block between top and bottom faces (not shown) ... 441.12 to 441.33 mm (17.367 to 17.375 in)
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Group cross 101609-3301 ZEXEL
Komatsu
101609-3301
9 400 615 897
3863452
INJECTION-PUMP ASSEMBLY
6BT-C
6BT-C