Information injection-pump assembly
BOSCH
9 400 614 443
9400614443
ZEXEL
101492-3510
1014923510
KOMATSU
6204711230
6204711230
Rating:
Service parts 101492-3510 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 443
9400614443
ZEXEL
101492-3510
1014923510
KOMATSU
6204711230
6204711230
Zexel num
Bosch num
Firm num
Name
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
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
1-2-4-3
Pre-stroke
mm
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.5
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
37.5
36.5
38.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10.5+-0.
5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
10.5
9.5
11.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=17 R1=(17.5)mm N1=1250r/min N2=800r/min N3=1250r/min N4=500r/min
----------
----------
K=17 R1=(17.5)mm N1=1250r/min N2=800r/min N3=1250r/min N4=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=15deg+-5deg b=32deg+-3deg c=35deg+-5deg
----------
----------
a=15deg+-5deg b=32deg+-3deg c=35deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
1. Remove the plug from location (1). Install Tool (A) in the hole with the square end down. Move the governor control to the "ON" position until the rack stops against Tool (A). The racks are now in center (zero) position. 2. Disconnect lines (2) from the fuel injection pumps. Remove washers (3). Put caps on all fuel openings.3. Remove bushing (4) with Tool (B).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
4. Remove fuel injection pump with Tool (C).
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. 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.
5. Disassemble the fuel injection pump. Remove ring (6). Make a separation of bonnet (5) from the plunger and barrel assembly (7).
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.
6. Remove the plunger and gear segment, washer and spring from the barrel.7. Remove the ring, spring, collar and valve from the barrel. 8. Remove spacer (8) from the pump bore.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed. 1. Put plunger (10), washer (5) and spring (9) in position on barrel (4). Put check valve assembly (7), spring (3) and collar (8) in position in bonnet (6). Connect bonnet (6) and barrel (4) together with ring (2). Keep seal (1) with bonnet for use at installation. 2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each pump.3. Put the space in gear segment (11) in alignment with the groove in barrel (4). 4. Put the injection pump straight down into the housing bore so the space in gear segment (11) is in alignment with pin (12) and the groove in barrel (4) is in alignment with dowel (14). Use Tool (C) to install the pump. 5. Install the seal and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will turn into the threads of the pump housing with the fingers until it is even with the housing. Tighten bushing (15) to a torque of 205 14 Nm (150 10 lb ft) with Tool (B).6. Install washers (16).7. Connect the fuel lines to the injection pumps and tighten fuel line nuts to a torque of 40 7 Nm (30 5 lb ft) with Tool (D).8. Check for correct installation of the injection pumps with the engine stopped. See the topic "Installation of Injection Pump" in the Systems
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed back in their original location.
4. Remove fuel injection pump with Tool (C).
Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. 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.
5. Disassemble the fuel injection pump. Remove ring (6). Make a separation of bonnet (5) from the plunger and barrel assembly (7).
Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.
6. Remove the plunger and gear segment, washer and spring from the barrel.7. Remove the ring, spring, collar and valve from the barrel. 8. Remove spacer (8) from the pump bore.Install Fuel Injection Pumps
Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed. 1. Put plunger (10), washer (5) and spring (9) in position on barrel (4). Put check valve assembly (7), spring (3) and collar (8) in position in bonnet (6). Connect bonnet (6) and barrel (4) together with ring (2). Keep seal (1) with bonnet for use at installation. 2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each pump.3. Put the space in gear segment (11) in alignment with the groove in barrel (4). 4. Put the injection pump straight down into the housing bore so the space in gear segment (11) is in alignment with pin (12) and the groove in barrel (4) is in alignment with dowel (14). Use Tool (C) to install the pump. 5. Install the seal and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will turn into the threads of the pump housing with the fingers until it is even with the housing. Tighten bushing (15) to a torque of 205 14 Nm (150 10 lb ft) with Tool (B).6. Install washers (16).7. Connect the fuel lines to the injection pumps and tighten fuel line nuts to a torque of 40 7 Nm (30 5 lb ft) with Tool (D).8. Check for correct installation of the injection pumps with the engine stopped. See the topic "Installation of Injection Pump" in the Systems