101609-3362 ZEXEL 9 400 611 608 BOSCH INJECTION-PUMP ASSEMBLY 9400611608 1016093362 3863595

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 608 9400611608

ZEXEL 101609-3362 1016093362

KOMATSU 3863595 3863595

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Buy INJECTION-PUMP ASSEMBLY 101609-3362 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3362 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9990

3. GOVERNOR 105404-5312

4. SUPPLY PUMP 105220-5610

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:

101609-3362 as INJECTION-PUMP ASSEMBLY

Include in #2:

104258-5182 as _

Cross reference number

BOSCH 9 400 611 608 9400611608

ZEXEL 101609-3362 1016093362

KOMATSU 3863595 3863595

Zexel num

Bosch num

Firm num

Name

101609-3362

9 400 611 608

3863595 KOMATSU

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

101609-3362

9 400 611 608

6735711240 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 9.4

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 92 91 93

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 50.7 50.7

Boost pressure mmHg 380 380

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-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 *

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. 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 800 800 800

Rack position R1-1.25

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(9.4)

Boost pressure kPa 37.3 37.3 37.3

Boost pressure mmHg 280 280 280

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
----------
K=17 BCL=1.25+-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)Use the center hole at R = aa
----------
aa=80mm
----------
a=49deg+-3deg b=29deg+-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:

(1) Fuel pump adapter assembly diameter ... 88.864 to 88.887 mm (3.4986 to 3.4995 in.) Bore diameter in cylinder block for fuel pump adapter assembly and upper thrust collar ... 88.90 to 88.936 mm (3.500 to 3.5014 in.)Clearance of adapter assembly in cylinder block ... 0.013 to 0.071 mm (.0005 to .0028 in.)(2) Inside diameter of bushing in adapter assembly ... 47.625 to 47.666 mm (1.8750 to 1.8766 in.) Upper fuel pump drive shaft diameter ... 47.533 to 47.574 mm (1.8714 to 1.8730 in.)Clearance of drive shaft in adapter assembly bushing ... 0.05 to 0.132 mm (.002 to .0052 in.)(3) Outside diameter of upper thrust collar ... 88.80 to 88.85 mm (3.496 to 3.498 in.) Clearance of upper thrust collar in block ... 0.05 to 0.137 mm (.002 to .0054 in.)Inside diameter of upper thrust collar ... 47.90 to 48.01 mm (1.886 to 1.890 in.)Clearance of fuel pump drive shaft in thrust collar ... 0.33 to 0.472 mm (.013 to .0186 in.)Width of groove in upper thrust collar ... 2.431 to 2.456 mm (.0957 to .0967 in.)(4) Upper thrust collar sealing ring thickness ... 2.357 to 2.383 mm (.0928 to .0938 in.) Clearance of sealing ring in groove ... 0.048 to 0.099 mm (.0019 to .0039 in.)(5) Bore diameter in cylinder block for lower thrust bearing ... 57.127 to 57.147 mm (2.2491 to 2.2499 in.) Lower thrust bearing bore diameter for bushing ... 45.242 to 45.283 mm (1.7812 to 1.7828 in.)(6) Outer diameter of bushing ... 45.321 to 45.357 mm (1.7843 to 1.7857 in.) Interference fit of bushing in lower thrust bearing ... 0.038 to 0.114 mm (.0015 to .0045 in.)Inside diameter of bushing (after reaming) ... 41.288 to 41.316 mm (1.6255 to 1.6266 in.)Lower diameter of fuel pump drive shaft ... 41.184 to 41.209 mm (1.6214 to 1.6224 in.)Clearance of fuel pump drive shaft in bushing ... 0.079 to 0.132 mm (.0031 to .0052 in.)(7) Auxiliary drive shaft rear bushing: Outside diameter of bushing ... 35.778 to 35.827 mm (1.4086 to 1.4105 in.)Bore diameter in cylinder block for rear bushing ... 35.720 to 35.753 mm (1.4063 to 1.4076 in.)Interference fit of bushing in cylinder block ... 0.03 to 0.107 mm (.001 to .0042 in.)Inside diameter of installed bushing ... 31.75 to 31.799 mm (1.25 to 1.2519 in.)Running clearance of auxiliary drive shaft in bushing ... 0.03 to 0.099 mm (.001 to .0039 in.)(8) Torque for auxiliary drive shaft gear bolts ... 30 N m (22 lb.ft.)(9) Auxiliary drive shaft gear bore diameter ... 25.40 to 25.43 mm (1.000 to 1.001 in.)(10) Auxiliary drive shaft thrust washers: Thickness ... 4.763 to 4.839 mm (.1875 to .1905 in.)Cylinder block recess depth for thrust washer ... 4.67 to 4.75 mm (.184 to .187 in.)Projection of thrust washer above cylinder block front face ... 0.013 to 0.18 mm (.0005 to .007 in.)Outside