Buy 101609-3712 ZEXEL F 01G 003 002 BOSCH INJECTION-PUMP ASSEMBLY f01g003002 1016093712 4063622

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 003 002 f01g003002

ZEXEL 101609-3712 1016093712

KOMATSU 4063622 4063622

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£1,985.47

31 Oct 2018

Robert Bos: Robert Bosch GmbH Au

Bosch F01G003002 Fuel-Injection Pump

Service parts 101609-3712 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9340

3. GOVERNOR 105404-6002

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105158-5002

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105088-2002

14. NOZZLE

105017-2910

15. NOZZLE SET

Include in #1:

101609-3712 as INJECTION-PUMP ASSEMBLY

Include in #2:

104265-4072 as _

Cross reference number

BOSCH F 01G 003 002 f01g003002

ZEXEL 101609-3712 1016093712

KOMATSU 4063622 4063622

Zexel num

Bosch num

Firm num

Name

101609-3712

F 01G 003 002

4063622 KOMATSU

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

101609-3712

F 01G 003 002

6738711150 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 11

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 130.5 129.5 131.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 70 70

Boost pressure mmHg 525 525

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 11 10 12

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 *

Injection quantity adjustment_03

Adjusting point E

Rack position 11.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 95 105

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Injection quantity adjustment_04

Adjusting point F

Rack position R1(11)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 133 123 143

Fixing the lever *

Boost pressure kPa 70 70

Boost pressure mmHg 525 525

Hydraulic cylinder ON *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position 8.9

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1-1.3

Boost pressure kPa 30.7 29.4 32

Boost pressure mmHg 230 220 240

Boost compensator adjustment_03

Pump speed r/min 800 800 800

Rack position R1(11)

Boost pressure kPa 56.7 56.7 56.7

Boost pressure mmHg 425 425 425

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=16 P1=127+-10kPa(1.3+-0.1kgf/cm2) BCL=(2.1)mm N1=1000r/min N2=450r/min
----------

Speed control lever angle

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

----------
a=12deg+-5deg b=33.5deg+-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.
----------
h=2.6+-0.01mm c=5deg15min+-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=10.5deg bb=0deg cc=2.6+-0.01mm
----------
a=55deg18min+-3deg b=55deg18min+-3deg13min48sec c=5deg15min+-30min

Information:

2. Remove pipe (1) and the gasket between aftercooler cover (2) and the turbocharger. If necessary, remove the O-ring seals from the pipe.3. Remove the bolts and clamps that hold tube assemblies (3) to each end of the aftercooler. Remove tube assemblies (3) from each end of the aftercooler. If necessary, remove the O-ring seals from the tube assemblies. An O-ring seal on each end of the aftercooler core holds the adapters in position.4. Remove adapters (4) and the gaskets from each end of the aftercooler.5. Remove all bolts (5) that hold aftercooler cover (2) in position. Remove the aftercooler cover and gasket from the engine. 6. Remove aftercooler core (6) and the gasket from the engine. If necessary, remove the O-ring seals from the aftercooler core. Two of the bolts that hold the aftercooler housing in position are on the inside of the aftercooler housing.7. Remove the bolts and spacers that hold aftercooler housing (7) to the engine. Make a note of the location of the spacers. Remove the aftercooler housing and gaskets from the engine.Install Aftercooler
Inspect all O-ring seals and gaskets, and make replacements if necessary. 1. Put the gaskets and aftercooler housing (1) in position on the engine. Install the bolts and spacers that hold the aftercooler housing.2. Install the O-ring seals on the aftercooler core, and put a thin layer of clean engine oil on them. Put the gasket and aftercooler core (2) in position on the engine. 3. Put the gasket and aftercooler cover (3) in position. Install the bolts that hold the aftercooler cover. Force may be required to push the adapters around the O-ring seals on the aftercooler core. Make sure the O-ring seals stay in position on the aftercooler core.4. Put a thin layer of clean engine oil in the bores of adapters (4). Install a gasket and adapter on each end of the aftercooler core. 5. Install the O-ring seals on tube assemblies (5), and put a thin layer of clean engine oil on them. Put the tube assemblies in position on each end of the aftercooler, and install the bolts and clamps that hold them.6. Install the O-ring seals on pipe (6), and put a thin layer of clean engine oil on them. Put the pipe and gasket in position between the aftercooler and the turbocharger. Install the bolts that hold it.7. Fill the radiator with coolant to the correct level. See the Operation & Maintenance Manual.