Information injection-pump assembly
BOSCH
9 400 610 199
9400610199
ZEXEL
101601-3382
1016013382
KOMATSU
6138721310
6138721310
Rating:
Service parts 101601-3382 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6138-12-3300
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 199
9400610199
ZEXEL
101601-3382
1016013382
KOMATSU
6138721310
6138721310
Zexel num
Bosch num
Firm num
Name
9 400 610 199
6138721310 KOMATSU
INJECTION-PUMP ASSEMBLY
SA6D110 K 14BF INJECTION PUMP ASSY PE6AD PE
SA6D110 K 14BF INJECTION PUMP ASSY PE6AD PE
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
1-5-3-6-
2-4
Pre-stroke
mm
4
3.95
4.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
94
93
95
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
41.3
41.3
Boost pressure
mmHg
310
310
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.4+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
15.5
14.3
16.7
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
10.7
Boost pressure
kPa
5.3
2.6
8
Boost pressure
mmHg
40
20
60
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.8
Boost pressure
kPa
28
28
28
Boost pressure
mmHg
210
210
210
Timer adjustment
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
1.5
1
2
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
3.2
2.7
3.7
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
5
4.5
5.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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)Boost compensator stroke
(4)Rack difference between N = N1 and N = N2
(5)Rack difference between N = N3 and N = N4
----------
K=12 N1=1100r/min N2=400r/min N3=1100r/min N4=750r/min
----------
----------
K=12 N1=1100r/min N2=400r/min N3=1100r/min N4=750r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=0deg+-5deg b=22deg+-5deg
----------
----------
a=0deg+-5deg b=22deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)At shipping
----------
----------
a=21deg+-5deg b=(52deg)
----------
----------
a=21deg+-5deg b=(52deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(0deg)
----------
----------
a=(0deg)
Information:
Above Normal Heating
Recommended Procedure
1. Low Coolant Level ... If the coolant level is too low, not enough coolant will go through the engine and radiator. This lack of coolant will not take enough heat from the engine and there will not be enough flow of coolant through the radiator to release the heat into the cooling air. Low coolant level is caused by leaks or wrong filling of the radiator. With the engine cool, be sure that coolant can be seen at the low end of the fill neck on the radiator top tank.2. Bad Temperature Gauge ... A temperature gauge which does not work correctly will not show the correct temperature. If the temperature gauge shows that the coolant temperature is too hot but other conditions are normal, either install a gauge you know is good or check the cooling system with the 8T0470 Thermistor Thermometer Group.3. Dirty Radiator ... Check the radiator for debris between the fins of the radiator core which prevents free air flow through the radiator core. Check the radiator for debris, dirt, or deposits on the inside of the radiator core which prevents free flow of coolant through the radiator.4. Loose Belt(s) ... Loose fan belts will cause a reduction in air flow. Tighten the belts according to V-Belt Tension Chart that is shown in Specification section of this Service Manual.5. Bad Hose(s) ... Bad hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside of a hose can deterioriate, and the loose particles of the hose can cause a restriction in the flow of coolant.6. Shunt Line Restriction ... A restriction of the shunt line from the radiator top tank to the engine water pump inlet, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and overheating.7. Shutters Not Opening Correctly ... Check the opening temperature of the shutters. The shutters must be completely closed at a temperature below the fully open temperature of the water temperature regulators.8. Bad Water Temperature Regulator(s) ... A regulator that does not open, or only opens part of the way, can cause above normal heating. To test the thermostats, see the Testing and Adjusting section of this Service Manual.9. Bad Water Pump ... A water pump with a loose or damaged impeller does not pump enough coolant for correct engine cooling. Remove the water pump and check for damage to the impeller. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and the housing is 0.28 to 0.84 mm (.011 to .033 in).10. Air in Cooling System ... Air can get into the cooling system in different ways. The most common causes
Recommended Procedure
1. Low Coolant Level ... If the coolant level is too low, not enough coolant will go through the engine and radiator. This lack of coolant will not take enough heat from the engine and there will not be enough flow of coolant through the radiator to release the heat into the cooling air. Low coolant level is caused by leaks or wrong filling of the radiator. With the engine cool, be sure that coolant can be seen at the low end of the fill neck on the radiator top tank.2. Bad Temperature Gauge ... A temperature gauge which does not work correctly will not show the correct temperature. If the temperature gauge shows that the coolant temperature is too hot but other conditions are normal, either install a gauge you know is good or check the cooling system with the 8T0470 Thermistor Thermometer Group.3. Dirty Radiator ... Check the radiator for debris between the fins of the radiator core which prevents free air flow through the radiator core. Check the radiator for debris, dirt, or deposits on the inside of the radiator core which prevents free flow of coolant through the radiator.4. Loose Belt(s) ... Loose fan belts will cause a reduction in air flow. Tighten the belts according to V-Belt Tension Chart that is shown in Specification section of this Service Manual.5. Bad Hose(s) ... Bad hoses with leaks can normally be seen. Hoses that have no visual leaks can "collapse" (pull together) during operation and cause a restriction in the flow of coolant. Hoses become soft and/or get cracks after a period of time. Hoses must be changed after 50,000 miles or a year of use. The inside of a hose can deterioriate, and the loose particles of the hose can cause a restriction in the flow of coolant.6. Shunt Line Restriction ... A restriction of the shunt line from the radiator top tank to the engine water pump inlet, or a shunt line not installed correctly, will cause a reduction in water pump efficiency. The result will be low coolant flow and overheating.7. Shutters Not Opening Correctly ... Check the opening temperature of the shutters. The shutters must be completely closed at a temperature below the fully open temperature of the water temperature regulators.8. Bad Water Temperature Regulator(s) ... A regulator that does not open, or only opens part of the way, can cause above normal heating. To test the thermostats, see the Testing and Adjusting section of this Service Manual.9. Bad Water Pump ... A water pump with a loose or damaged impeller does not pump enough coolant for correct engine cooling. Remove the water pump and check for damage to the impeller. If the impeller has no damage, check the impeller clearance. The clearance between the impeller and the housing is 0.28 to 0.84 mm (.011 to .033 in).10. Air in Cooling System ... Air can get into the cooling system in different ways. The most common causes