101609-3620 ZEXEL 9 400 612 499 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 612 499 9400612499
ZEXEL 101609-3620 1016093620

Service parts 101609-3620 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9990
3. GOVERNOR 105404-5860
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 4063212
12. Open Pre:MPa(Kqf/cm2) 22.0{224}
13. NOZZLE-HOLDER 105088-2002
14. NOZZLE 105017-2910
15. NOZZLE SET

Include in #1:

101609-3620 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 612 499 9400612499
ZEXEL 101609-3620 1016093620


Zexel num Bosch num Firm num Firm Name
101609-3620 
101609-3621 
9 400 612 499      INJECTION-PUMP ASSEMBLY
* K

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   6-2-600
Outer diameter - inner diameter - length (mm)
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-5-3-6- 2-4
Pre-stroke mm   2.45 2.4 2.5
Beginning of injection position   NO.1
Drive side
Difference between angles 1 deg.   60 59.5 60.5
Cal 1-5
Difference between angles 2 deg.   120 119.5 120.5
Cal 1-3
Difference between angles 3 deg.   180 179.5 180.5
Cal 1-6
Difference between angles 4 deg.   240 239.5 240.5
Cyl.1-2
Difference between angles 5 deg.   300 299.5 300.5
Cal 1-4


Injection quantity adjustment
Adjusting point   A
Rack position   12.4
Pump speed r/min   1025 1025 1025
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   56 56
Boost pressure mmHg   420 420


Injection quantity adjustment_02
Adjusting point   -
Rack position   7.8+-0.5
Pump speed r/min   525 525 525
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
Remarks  
Adjust only variation between cylinders; adjust governor according to governor specifications.


Injection quantity adjustment_03
Adjusting point   E
Rack position   13++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   110 110 120
Fixing the lever   *
Boost pressure kPa   56 56
Boost pressure mmHg   420 420
Rack limit   *


Boost compensator adjustment
Pump speed r/min   850 850 850
Rack position   R1-1.9
Boost pressure kPa   29.3 29.3 29.3
Boost pressure mmHg   220 220 220


Boost compensator adjustment_02
Pump speed r/min   850 850 850
Rack position   R1-1.3
Boost pressure kPa   32 30.7 33.3
Boost pressure mmHg   240 230 250


Boost compensator adjustment_03
Pump speed r/min   850 850 850
Rack position   R1(12.4)
Boost pressure kPa   42.7 42.7 42.7
Boost pressure mmHg   320 320 320

Test data Ex:



Governor adjustment

Test data 101609-3620 N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)It is not necessary to supply hydraulic pressure because the specification is for the hydraulic ACT normally ON. (4)RACK LIMIT (5)Boost compensator stroke: BCL
----------
K=13 BCL=1.9+-0.1mm
----------



Speed control lever angle

Test data 101609-3620 F:Full speed I:Idle S:Stop (1)At hole at R = aa (center) (2)Rack position = bb, speed = cc
----------
aa=77mm bb=1-0.5mm cc=0r/min
----------
a=(10deg)+-5deg b=31deg+-3deg c=(30deg)+-5deg



Timing setting

Test data 101609-3620 (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=13deg bb=0deg
----------
a=54deg36min+-3deg b=6deg30min+-30min





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Group cross 101609-3620 ZEXEL

101609-3600 
101609-3601 
9 400 612 172    INJECTION-PUMP ASSEMBLY

Komatsu 

101609-3601  F 01G 0V0 000  4063335  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3601  F 01G 0V0 000  6738711110  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3610      INJECTION-PUMP ASSEMBLY
101609-3611 
101609-3612 
9 400 612 930    INJECTION-PUMP ASSEMBLY

Komatsu 

101609-3612  9 400 613 438  4063354  INJECTION-PUMP ASSEMBLY
6BTAA5.9
101609-3612  9 400 613 438  6738711510  INJECTION-PUMP ASSEMBLY
6BTAA5.9
101609-3620 
101609-3621 
9 400 612 499    INJECTION-PUMP ASSEMBLY

Komatsu 

101609-3621  9 400 612 566  4063361  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3621  9 400 612 566  6738711130  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3630  9 400 615 912  3864090  INJECTION-PUMP ASSEMBLY
6D102E
101609-3630  9 400 615 912  6734711340  INJECTION-PUMP ASSEMBLY
6D102E
101609-3640  F 01G 0V0 001  4063209  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3640  F 01G 0V0 001  6738711210  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3650  F 01G 0V0 002  4063208  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3650  F 01G 0V0 002  6738711310  INJECTION-PUMP ASSEMBLY
6BTAA
101609-3660  F 01G 0V0 003  3939727  INJECTION-PUMP ASSEMBLY
SAA6D102E
101609-3660  F 01G 0V0 003  6738711140  INJECTION-PUMP ASSEMBLY
SAA6D102E
101609-3690  F 01G 003 000  4063620  INJECTION-PUMP ASSEMBLY
SAA6D102E
101609-3690  F 01G 003 000  6738711160  INJECTION-PUMP ASSEMBLY
SAA6D102E
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