Buy 101609-3690 ZEXEL F 01G 003 000 BOSCH INJECTION-PUMP ASSEMBLY f01g003000 1016093690 4063620

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 003 000 f01g003000

ZEXEL 101609-3690 1016093690

KOMATSU 4063620 4063620

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Genuine Cummins 4063620 PUMP,INJECTION ZEXEL A

$3,539.94

30 Jul 2020

-: -

Genuine Cummins 4063620 PUMP,INJECTION ZEXEL A
Factory Direct Shipped Genuine Cummins Part || Availability can vary, please contact for availability before ordering || May take up to 20 business days to ship. Shipping depends upon availability

Service parts 101609-3690 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9340

3. GOVERNOR 105404-5960

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105158-5012

11. Nozzle and Holder 4063269

12. Open Pre:MPa(Kqf/cm2) 22.0{224}

13. NOZZLE-HOLDER 105088-2002

14. NOZZLE

105017-2910

15. NOZZLE SET

Include in #1:

101609-3690 as INJECTION-PUMP ASSEMBLY

Include in #2:

104214-0170 as _

Cross reference number

BOSCH F 01G 003 000 f01g003000

ZEXEL 101609-3690 1016093690

KOMATSU 4063620 4063620

Zexel num

Bosch num

Firm num

Name

101609-3690

F 01G 003 000

4063620 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102E K 14BE INJECTION PUMP ASSY PE6A PE

101609-3690

F 01G 003 000

6738711160 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA6D102E 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 2.6 2.55 2.65

Rack position
After adjusting injection quantity. R=A

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 9.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 101.5 100.5 102.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 100 100

Boost pressure mmHg 750 750

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point -

Rack position 7+-0.5

Pump speed r/min 420 420 420

Average injection quantity mm3/st. 9.5 8.5 10.5

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 E

Rack position 10.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 75 85

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 700 700 700

Rack position 8.8

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 9.4

Boost pressure kPa 56 54.7 57.3

Boost pressure mmHg 420 410 430

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position 10

Boost pressure kPa 86.6 86.6 86.6

Boost pressure mmHg 650 650 650

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 (When hydraulic cylinder is OFF) (4)When hydraulic cylinder ON: P1 (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=17 P1=(127+-10kPa{1.3+-0.1kgf/cm2}) BCL=1.2+-0.1mm N1=1000r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=16deg+-5deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
----------
T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
----------

0000001601 I/P WITH LOAD PLUNGER ADJ

Adjusting procedure for load plunger equipped pump with RSV (cam lock) governor (see service information S.I. 434 for details). At cam lift h+-0.01, set the camshaft c deg from the * mark in accordance with the timing adjustment procedure. 2. Align the flyweight's timing tooth position and the lock pin groove and then fully tighten the flyweight to the camshaft. Then, remove the lock pin. 3. Adjust the maximum variation between cylinders and injection quantity. 4. Adjust using the pre-stroke adjusting shim so that the pre-stroke value is the value for 4/4 load (standard point A). 5. After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation between cylinders are as specified. 6. At delivery, again fix the flyweight using the lock pin.
----------
t=1mm h=2.6+-0.01mm c=5deg+-30min
----------

Timing setting

(1)Pump vertical direction (2)Key groove position for No. 1 cylinder's cam lift h = cc (at BTDC aa). (3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity adjustment). (4)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). (5)B.T.D.C.: aa
----------
aa=10deg bb=0deg cc=2.6+-0.01mm
----------
a=55deg18min+-3deg b=55deg18min+-3deg13min48sec c=5deg+-30min

Information:

Start By:a. remove governor 1. Remove the bolts and the plate from the side of the fuel injection pump housing.2. Install Tool (A) in the fuel injection pump housing. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.3. Use Tool (B) to remove bushing (1) from the fuel injection pump housing.4. Remove the O-ring seal from the fuel injection pump housing. Spacers (2) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and can not be mixed.5. Install Tool (C) on the bonnet. Remove the fuel injection pump. 6. Remove spacer (2) from the fuel injection pump housing.7. Do Steps 3 through 6 to remove the other fuel injection pumps.Install Fuel Injection Pumps
1. Install spacer (1) in the fuel injection pump housing. 2. Install Tool (A) in the fuel injection pump housing. Move the rack until Tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Turn the camshaft until the lobe of the camshaft is down for the pump to be installed.4. Install Tool (B) on the bonnet of the fuel injection pump.5. Install the fuel injection pump in the pump housing with saw cut (slot) (3) in the gear in alignment with the small pin (2) and groove (4) in the barrel in alignment with dowel (5) in the pump housing. 6. Put clean oil on O-ring seal (6). Install it in the fuel injection pump housing.7. Install the bushing by hand until it is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump, and put the pump in alignment again, and install the bushing again. 8. Install Tool (C) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft). 9. Install Tool (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of incorrect fuel injection pump installation.10. Do Steps 1 through 9 again for installation of the other fuel pumps.11. Install the cover and gasket on the fuel injection pump housing.End By:a. install governorDisassemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
Be careful when the injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
1. Pull plunger (1) and