101609-3351 ZEXEL 9 400 615 899 BOSCH INJECTION-PUMP ASSEMBLY 9400615899 1016093351 3863709

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 899 9400615899

ZEXEL 101609-3351 1016093351

KOMATSU 3863709 3863709

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Buy INJECTION-PUMP ASSEMBLY 101609-3351 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5301

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:

101609-3351 as INJECTION-PUMP ASSEMBLY

Include in #2:

104258-5192 as _

Cross reference number

BOSCH 9 400 615 899 9400615899

ZEXEL 101609-3351 1016093351

KOMATSU 3863709 3863709

Zexel num

Bosch num

Firm num

Name

101609-3351

9 400 615 899

3863709 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D102E K 14BE INJECTION PUMP ASSY PE6A PE

101609-3351

9 400 615 899

6735711181 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D102E 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 131424-3420

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 9.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 89 88 90

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 14 13 15

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.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

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 675 675 675

Rack position 8.9

Boost pressure kPa 8 6.7 9.3

Boost pressure mmHg 60 50 70

Boost compensator adjustment_02

Pump speed r/min 675 675 675

Rack position 9.85

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

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)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (When hydraulic cylinder is OFF) (5)Boost compensator stroke: BCL (6)When hydraulic cylinder ON: P1 (7)Rack difference between N = N1 and N = N2
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K=11 BCL=0.95+-0.1mm P1=((392)kPa{(4)kgf/cm2}) N1=1000r/min N2=675r/min
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Speed control lever angle

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

----------
a=11deg+-5deg b=28deg+-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=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min

Information:

(1) Outer spring: Length under test force ... 27.4 mm (1.08 in.)Test force ... 180 9 N (40 2 lb.)Free length after test ... 45.2 mm (1.78 in.)(Damper coils of spring go toward cylinder head.)(2) Inner spring: Length under test force ... 23.88 mm (.940 in.)Test force ... 69 9 N (15.4 2 lb.)Free length after test ... 39.6 mm (1.56 in.)(Damper coils of spring go toward cylinder head.)(3) Valve guides: Inside diameter ... 9.507 to 9.543 mm (.3743 to .3757 in.)Outside diameter ... 15.921 to 15.933 mm (.6268 to .6273 in.)Parent bore diameter in cylinder head for valve guide ... 15.867 to 15.893 mm (.6247 to .6257 in.)Interference fit of guide in cylinder head ... 0.028 to 0.066 mm (.0011 to .0026 in.)Overall length of guide: Intake ... 57.94 mm (2.281 in.)Exhaust ... 61.11 mm (2.406 in.)Projection of guide above valve spring recess ... 15.09 mm (.594 in.)(4) Intake valve: Valve stem diameter ... 9.42 to 9.45 mm (.371 to .372 in.)Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in.)Maximum permissible clearance of valve in guide ... 0.13 mm (.005 in.)Valve head diameter ... 44.09 to 44.35 mm (1.736 to 1.746 in.) Grinding angles: Valve face angle ... 45°Valve seat angle ... 45°Valve head depth below cylinder head face: Minimum ... 1.02 mm (.040 in.)Maximum ... 1.27 mm (.050 in.)Service wear limit ... 1.52 mm (.060 in.)Overall length of valve ... 122.71 to 123.11 mm (4.831 to 4.847 in.)(5) Exhaust valve: Valve stem diameter ... 9.42 to 9.45 mm (.371 to .372 in.)Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in.)Maximum permissible clearance of valve in guide (all models) ... 0.15 mm (.006 in.)Valve head diameter ... 37.26 to 37.52 mm (1.467 to 1.477 in.)Grinding angles: Valve face angle ... 45°Valve seat angle ... 45°Valve head depth below cylinder head face: Minimum ... 1.02 mm (.040 in.)Maximum ... 1.27 mm (.050 in.)Service wear limit ... 1.52 mm (.060 in.)Overall length of valve ... 123.11 to 123.52 mm (4.847 to 4.863 in.)(6) Maximum permissible depth of bore to grind the flare of the valve seat ... 2.69 to 2.79 mm (.106 to .110 in.)(7) Angle to grind flare of valve seat ... 33° (8) Use the dimensions that follow to machine the recess into the cylinder head for valve seat inserts not already installed in the head. Intake: A ... 7.19 to 7.32 mm (.283 to .288 in.)B ... 51.219 to 51.245 mm (2.0165 to 2.0175 in.)C (Radius) ... 0.38 mm (.015 in.)Exhaust: A ... 9.53 to 9.65 mm (.375 to .380 in.)B ... 42.62 to 42.65 mm (1.678 to 1.679 in.)C (Radius) ... 0.38 mm (.015 in.)