101609-3301 ZEXEL 9 400 615 897 BOSCH INJECTION-PUMP ASSEMBLY 9400615897 1016093301 3863452


101609-3301 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 897 9400615897
ZEXEL 101609-3301 1016093301
KOMATSU 3863452 3863452

Service parts 101609-3301 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9990
3. GOVERNOR 105404-5170
4. SUPPLY PUMP 105220-5690
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) 21.6{220}
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

101609-3301 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 897 9400615897
ZEXEL 101609-3301 1016093301
KOMATSU 3863452 3863452


Zexel num
Bosch num
Firm num
Name
101609-3301 
9 400 615 897 
3863452  KOMATSU
INJECTION-PUMP ASSEMBLY
6BT-C K

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   1150 1150 1150
Average injection quantity mm3/st.   81 80 82
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   42.7 42.7
Boost pressure mmHg   320 320
Hydraulic cylinder ON   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.4+-0.5
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   15 14 16
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   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 80 90
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   750 750 750
Rack position   R1-0.5
Boost pressure kPa   16 16 16
Boost pressure mmHg   120 120 120
Boost compensator adjustment_02
Pump speed r/min   750 750 750
Rack position   R1(8.9)
Boost pressure kPa   29.3 22.6 36
Boost pressure mmHg   220 170 270

Test data Ex:

Governor adjustment

Test data 101609-3301
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Set idle sub-spring (7)Main spring setting (8)Boost compensator stroke: BCL (9)When hydraulic cylinder ON: P1
----------
K=10 BCL=0.5+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------

Speed control lever angle

Test data 101609-3301
F:Full speed I:Idle (1)Stopper bolt setting (2)At hole at R = aa (center)
----------
aa=80mm
----------
a=36deg+-3deg b=20deg+-5deg

Stop lever angle

Test data 101609-3301
N:Pump normal S:Stop the pump. (1)No return spring
----------

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

Timing setting

Test data 101609-3301
(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




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