Information injection-pump assembly
BOSCH
9 400 615 908
9400615908
ZEXEL
101609-3501
1016093501
KOMATSU
3863866
3863866
Rating:
Include in #2:
104258-5142
as _
Cross reference number
BOSCH
9 400 615 908
9400615908
ZEXEL
101609-3501
1016093501
KOMATSU
3863866
3863866
Zexel num
Bosch num
Firm num
Name
101609-3501
9 400 615 908
3863866 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D102E K 14BE INJECTION PUMP ASSY PE6A PE
S6D102E K 14BE INJECTION PUMP ASSY PE6A PE
101609-3501
9 400 615 908
6735711411 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D102E K 14BE INJECTION PUMP ASSY PE6A PE
S6D102E K 14BE INJECTION PUMP ASSY PE6A PE
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
9
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
78
77
79
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
515
515
515
Average injection quantity
mm3/st.
9
8
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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.
70
70
80
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)RACK LIMIT
(4)Adjust the secondary timing before adjusting the governor.
----------
K=18
----------
----------
K=18
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=12deg+-5deg b=27deg+-5deg
----------
----------
a=12deg+-5deg b=27deg+-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=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min
----------
aa=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min
Information:
Group 2
1 - 6I0347 Bracket2 - 7C6591 Clamp2 - 7C7747 Clamp2 - 4B4274 Washer2 - 9N3388 Screw1 - 6I4813 Clamp Kit1 - 8T1296 Washer2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyGroup 3
2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See the attached procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the following instructions and illustrations. Replace the existing fuel lines and their related parts with the new fuel line groups.
To insure correct clamp locations, install left and right fuel line groups as assembled. However, if clamps are removed, mark locations to insure correct positions when reassembling.
On the 992C Wheel Loader, it is necessary to remove the 6N8322 Air Outlet Tube Assembly to be able to install the right bank fuel line group.
Tighten the fuel line clamp screws to a torque of 2.25 N m (20 lb in). Do not over tighten. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
Group 1 Procedure
1. Clean and paint the new 6I0361 and 7E3539 Fuel Line Groups before proceeding to the job site.A) "Tape Off" the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1 - Part 4 of 5, Section C-C)B) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.C) Clean and paint the fuel line groups.D) After drying completely, remove the tape. Do not remove the plastic caps and plugs until the fuel lines are ready to be installed on the engine. Transport the fuel line groups in their original boxes.2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.3. A) Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp As. that form the tower clamp will be reused. (See Illustration 1 - Part 4 of 5, Section C-C)B) Disconnect the 2 line clamps from the 9Y3361 Bracket (Front V Bracket).C) Disconnect the 6 line clamps from the 7E5779 Bracket (Large V Bracket).4. Disconnect all the fuel lines at the fuel injection pump and at the adaptors in the valve cover bases.5. A) Remove the left and right side fuel line groups as separate assemblies.B) Remove the 9Y3361 Bracket (Front V Bracket). Replace it with a new 6I0347 Bracket.6. Remove the plastic caps and plugs from the fuel lines. Set the new 6I0361 Fuel Lines Group (left side) and the new 7E3539 Fuel Lines Group (right side) in place and hand tighten the fuel nuts. (See Illustration 1 - Part 1 of 5). If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or with the adaptors in the valve cover bases, gently bend the lines
1 - 6I0347 Bracket2 - 7C6591 Clamp2 - 7C7747 Clamp2 - 4B4274 Washer2 - 9N3388 Screw1 - 6I4813 Clamp Kit1 - 8T1296 Washer2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyGroup 3
2 - 5P4939 Screw1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See the attached procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the following instructions and illustrations. Replace the existing fuel lines and their related parts with the new fuel line groups.
To insure correct clamp locations, install left and right fuel line groups as assembled. However, if clamps are removed, mark locations to insure correct positions when reassembling.
On the 992C Wheel Loader, it is necessary to remove the 6N8322 Air Outlet Tube Assembly to be able to install the right bank fuel line group.
Tighten the fuel line clamp screws to a torque of 2.25 N m (20 lb in). Do not over tighten. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
Group 1 Procedure
1. Clean and paint the new 6I0361 and 7E3539 Fuel Line Groups before proceeding to the job site.A) "Tape Off" the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1 - Part 4 of 5, Section C-C)B) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.C) Clean and paint the fuel line groups.D) After drying completely, remove the tape. Do not remove the plastic caps and plugs until the fuel lines are ready to be installed on the engine. Transport the fuel line groups in their original boxes.2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.3. A) Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp As. that form the tower clamp will be reused. (See Illustration 1 - Part 4 of 5, Section C-C)B) Disconnect the 2 line clamps from the 9Y3361 Bracket (Front V Bracket).C) Disconnect the 6 line clamps from the 7E5779 Bracket (Large V Bracket).4. Disconnect all the fuel lines at the fuel injection pump and at the adaptors in the valve cover bases.5. A) Remove the left and right side fuel line groups as separate assemblies.B) Remove the 9Y3361 Bracket (Front V Bracket). Replace it with a new 6I0347 Bracket.6. Remove the plastic caps and plugs from the fuel lines. Set the new 6I0361 Fuel Lines Group (left side) and the new 7E3539 Fuel Lines Group (right side) in place and hand tighten the fuel nuts. (See Illustration 1 - Part 1 of 5). If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or with the adaptors in the valve cover bases, gently bend the lines
Have questions with 101609-3501?
Group cross 101609-3501 ZEXEL
Komatsu
101609-3501
9 400 615 908
3863866
INJECTION-PUMP ASSEMBLY
S6D102E
S6D102E
101609-3501
9 400 615 908
6735711411
INJECTION-PUMP ASSEMBLY
S6D102E
S6D102E