Information injection-pump assembly
BOSCH
9 400 611 525
9400611525
ZEXEL
101609-3530
1016093530
KOMATSU
6221731230
6221731230
Rating:
Service parts 101609-3530 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6221-13-3300
12.
Open Pre:MPa(Kqf/cm2)
20.6{210}
15.
NOZZLE SET
Include in #1:
101609-3530
as INJECTION-PUMP ASSEMBLY
Include in #2:
104258-5310
as _
Cross reference number
BOSCH
9 400 611 525
9400611525
ZEXEL
101609-3530
1016093530
KOMATSU
6221731230
6221731230
Zexel num
Bosch num
Firm num
Name
101609-3530
9 400 611 525
6221731230 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D108E K
S6D108E K
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
3.6
3.55
3.65
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
9.7
Pump speed
r/min
1190
1190
1190
Average injection quantity
mm3/st.
97.5
96.5
98.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
46
46
Boost pressure
mmHg
345
345
Injection quantity adjustment_02
Adjusting point
B
Rack position
7+-0.5
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
10.5
9.3
11.7
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
60
70
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
750
750
750
Rack position
R1-1.1
Boost pressure
kPa
16.7
14
19.4
Boost pressure
mmHg
125
105
145
Boost compensator adjustment_02
Pump speed
r/min
750
750
750
Rack position
R1(9.7)
Boost pressure
kPa
32.4
25.7
39.1
Boost pressure
mmHg
245
195
295
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)Boost compensator stroke
----------
K=8
----------
----------
K=8
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=11deg+-5deg b=26deg+-5deg
----------
----------
a=11deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Stopper bolt setting
(3)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=42.5deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=42.5deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(50deg)
----------
aa=15deg
----------
a=(50deg)
Information:
Termination Date
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
January 31, 1993Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34325)
3208 (9WC1-730; 5CD1-5868; 62W1-68596; 93Z1-8374)
Remanufactured Fuel Pump Part Numbers
0R07660R09030R23840R23860R09020R23740R23850R2877 The above list of remanufactured pumps are affected only if they are stamped with a date code of 12/91 (UMDU) or earlier.
Parts Needed
Not Applicable
Action Required
Before installing or delivering any of the affected product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with: - Fuel Injector Cleaner or
- Carburetor/Choke Cleaner
4. Allow the components to soak in cleaning solution for 45 minutes, then rotate the engine crankshaft to rotate the fuel injection pump (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.5. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
It is a .5-hr. job to inspect the pump. An additional .5-hr. may be claimed if cleaning is required.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101609-3530?
Group cross 101609-3530 ZEXEL
Komatsu
101609-3530
9 400 611 525
6221731230
INJECTION-PUMP ASSEMBLY
S6D108E
S6D108E