101609-3341 ZEXEL 9 400 615 898 BOSCH INJECTION-PUMP ASSEMBLY 9400615898 1016093341 3863541

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 898 9400615898

ZEXEL 101609-3341 1016093341

KOMATSU 3863541 3863541

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Buy INJECTION-PUMP ASSEMBLY 101609-3341 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3341 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5170

4. SUPPLY PUMP

105220-5960

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:

101609-3341 as INJECTION-PUMP ASSEMBLY

Include in #2:

104144-3310 as _

Cross reference number

BOSCH 9 400 615 898 9400615898

ZEXEL 101609-3341 1016093341

KOMATSU 3863541 3863541

Zexel num

Bosch num

Firm num

Name

101609-3341

9 400 615 898

3863541 KOMATSU

INJECTION-PUMP ASSEMBLY
6BT-C 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 131424-3420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 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 C

Rack position 6.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

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 *

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)Boost compensator stroke: BCL (7)When hydraulic cylinder ON: P1
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K=10 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At hole at R = aa (center)
----------
aa=80mm
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a=36deg+-3deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
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

Information:

Lubrication System
OIL LUBRICATION SCHEMATICThe lubrication system is the pressure type. The oil pump draws oil from the sump through a suction pipe and strainer to the pump. The oil pump is driven by the auxiliary drive group which is driven by the timing gears.Pressure oil flows to the oil cooler. The oil cooler is cooled by water from the cooling system. Coolers on T6.3544 Engines have a bypass valve that allows the oil to go around the cooler in case of a restriction or if the oil is too cold and thick. From the cooler, oil passes through the relief valve. On T6.3544 Engines, the relief valve is two stage. At 205 to 225 kPa (30 to 37 psi), oil is fed by a pipe to the piston cooling jet gallery which is a drilled passage the length of the crankcase, above the camshaft chamber. The piston cooling jets are bolted into the gallery and point into the bottom of each cylinder. Oil is sprayed onto the underneath side of each piston which takes heat from the combustion area. The oil then drains back to sump.At 345 to 415 kPa (50 to 60 psi), oil passes through a single oil filter on 6.3544 Engines or two filters on T6.3544 Engines. Oil then flows to the main oil gallery which is a drilled passage the length of the crankcase. Oil also flows from the filters to the turbocharger bearings on T6.3544 Engines. Passages in the crankcase webs feed oil from the main oil gallery to the main bearings. Passages in the crankshaft carry oil to the big end bearings. Through passages in No. 1, 3, 5 and 7 crankcase webs, oil passes from the main bearings to lubricate the camshaft bearings.The No. 2 camshaft bearing supplies a controlled amount of oil to the rocker shaft assembly, which then flows through a small bleed hole in each rocker lever to lubricate the valves and springs.Pistons, cylinder liners, connecting rod small end bushings, cam lobes and valve lifters are splash and oil mist lubricated.Oil flows from the main oil gallery to the two idler gear hubs. The oil passes through the hubs to radial passages in the idler gears to lubricate the teeth of the timing gears.The auxiliary drive group shaft bearings are lubricated by a passage from the main oil gallery to the front auxiliary drive shaft bearing. Oil then passes around a groove in the bearing journal and through another passage along the outer side of the auxiliary drive housing to the rear auxiliary drive shaft bearing. The upper fuel pump bearing is also lubricated from this passage. Also connected to this outer housing passage is a spray tube which directs oil on to the auxiliary drive shaft (worn gear) and gear assembly (worm wheel).Air Inlet And Exhaust System
6.3544 Engines
AIR INLET AND EXHAUST SYSTEM COMPONENTS
1. Exhaust manifold. 2. Inlet manifold. 3. Engine cylinderThe air inlet and exhaust system components on naturally aspirated engines are: the air cleaner, inlet manifold,