101609-3420 ZEXEL 9 400 615 902 BOSCH INJECTION-PUMP ASSEMBLY 9400615902 1016093420 3863793

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 902 9400615902

ZEXEL 101609-3420 1016093420

KOMATSU 3863793 3863793

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Buy INJECTION-PUMP ASSEMBLY 101609-3420 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-3420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9050

3. GOVERNOR 105404-5420

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)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101609-3420 as INJECTION-PUMP ASSEMBLY

Include in #2:

104265-3020 as _

Cross reference number

BOSCH 9 400 615 902 9400615902

ZEXEL 101609-3420 1016093420

KOMATSU 3863793 3863793

Zexel num

Bosch num

Firm num

Name

101609-3420

9 400 615 902

3863793 KOMATSU

INJECTION-PUMP ASSEMBLY
6D102E K 14BE INJECTION PUMP ASSY PE6A PE

101609-3420

9 400 615 902

6734711270 KOMATSU

INJECTION-PUMP ASSEMBLY
6D102E 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 8.9

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 58.5 57.5 59.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60 70

Fixing the lever *

Rack limit *

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 (5)The torque control spring must does not have a set force.
----------
K=6
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Speed control lever angle

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

----------
a=5deg+-5deg b=19deg+-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:

Caterpillar: Confidential Yellow
PSP FOR FUEL INJECTION LINE FAILURES ON 627E, 627E PP AND 637E SCRAPERS - MAILED WORLDWIDE EXCEPT BRAZIL
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
U-35 A-20 AU-22 E-18 O-21 1252 PS4200 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4200" as Part Number and "7755" as Group Number. Termination Date
February 28, 1989
Problem
The fuel injection lines on 627E, 627E PP and 637E Scrapers may crack as a result of excessive vibration. New fuel injection lines and supporting brackets can be installed.
Affected Product
Model Identification Number 627E 6EBl - 513 627E PP 6GB513 - 177, 579-582, 584, 585, 587, 588, 590-603 637E 1FB1 - 338, 341-348, 350-352 1JB1 - 548, 550, 553, 555, 556, 558-561, 563
Parts Needed
1 - 7C9564 Line As. 1 - 7C9565 Line As. 1 - 7C9566 Line As. 11 - 1W9168 Clamp 8 - 5P4939 Screw As. 11 - lW9169 Clamp 1 - 9Y1586 Bracket As. 1 - 9Y1653 Bracket As. 3 - 9N3388 Screw 1 - 9Y2681 Bar (as needed) The 9Y2681 Bar is only needed if the engine is not equipped with heat shields.
Action Required
Install the new parts as shown in the attached illustration. It is important that the 1W9168 and 1W9169 Clamps be installed at the locations shown in the illustration.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-2500