Information injection-pump assembly
BOSCH
9 400 614 450
9400614450
ZEXEL
101492-3730
1014923730
KOMATSU
6204731210
6204731210
Rating:
Service parts 101492-3730 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
9 400 614 450
9400614450
ZEXEL
101492-3730
1014923730
KOMATSU
6204731210
6204731210
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
10.8
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
38.5
37.5
39.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.8+-0.5
Pump speed
r/min
495
495
495
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=14 R1=(17.5)mm N1=1050r/min N2=750r/min N3=1050r/min N4=350r/min
----------
----------
K=14 R1=(17.5)mm N1=1050r/min N2=750r/min N3=1050r/min N4=350r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=(9deg)+-5deg b=32deg+-3deg c=23deg+-5deg
----------
----------
a=(9deg)+-5deg b=32deg+-3deg c=23deg+-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 former fuel injection lines (1), the clamps and through-the-cover fuel line adapters (2) from the engine; these parts will not be needed again. Install 8M4437 Seals on twelve 1W6777 Adapters (3). Put engine oil on the seals and install the adapters in valve cover base assemblies (4) where adapters (2) were removed. Fasten the adapters to bases (4) with two 5N5365 Locks on each and the former nuts. Connect former fuel lines (5) to adapters (3) and the former fuel nozzle adapters. (2) Install a 2W2500 Washer (7) and a 6V6579 Seal (8) on each adapter (3). Install a 5P9267 Seal on each injector pump; put diesel fuel on the seals before installation. Loosely install fuel injection line assemblies: number "6" (9), number "12" (10), number "4" (11), number "2" (12), number "10" (13) and number "8" (14) on the right side of the engine between the fuel injection pumps and adapters (3). See the above chart for the correct part number of the fuel lines. Remove two bolts and install 5N5370 Bracket (15) and 5N5374 Clamp (16) where the bolts were removed. Fasten the fuel injection lines to bracket (15) with two 5N5369 Dampers, a 5N5371 Clamp and two 2W7884 Bolt Assemblies. Fasten the fuel injection lines to clamp (16) with two 5N5373 Dampers, a 5N5372 Clamp and two 2W7884 Bolts. Use 5N5957 and 5N5958 Clamps, two 5N5956 Dampers and a 2W7884 Bolt Assembly to fasten the fuel lines together at (A). Use 5N5376 and 5N5377 Clamps, two 5N5375 Dampers and three 2W7884 Bolt Assemblies to fasten the fuel lines together at (B). Tighten the bolt assemblies to 10 N m (7 lb.ft.) torque. Tighten nuts (17) on each end of the fuel injection lines to 40 7 N m (35 5 lb.ft.) torque, then tighten nuts (18).(3) Loosely install fuel injection line assemblies; number "11" (19), number "3" (20), number "7" (21), number "9" (22), number "5" (23) and number "1" (24) on the left side of the engine between adapters (3) and the fuel injection pump as shown. Remove a bolt and install 5N5370 Bracket (25) where the bolt was removed. Fasten the fuel lines to bracket (25) with two 5N5369 Dampers, a 5N5371 Clamp and two 2W7884 Bolts. On engines equipped with aftercooler, fasten 5N5379 Plate (26) to an existing bolt on the aftercooler. Fasten the fuel injection lines to plate (26) with two 5N5378 Dampers, a 5N5374 Clamp and two 2W7884 Bolt Assemblies. Use two 5N5376 and 5N5377 Clamps, four 5N5375 Dampers and four 2W7884 Bolt Assemblies to fasten the fuel lines together at locations (C). If the engine does not have an aftercooler, use 5N5957 and 5N5958 Clamps, two 5N5956 Dampers and a 2W7884 Bolt Assembly to fasten the fuel injection lines together at (D). Tighten the fuel lines as shown in step 2.2W5100 Fuel Lines Drain Group
(1) Install a 9L8496 Tee (1) in each adapter (2). Connect tees (1) together with ten 5N5940 Tube Assemblies (3).
(1) Install a 9L8496 Tee (1) in each adapter (2). Connect tees (1) together with ten 5N5940 Tube Assemblies (3).