Information injection-pump assembly
BOSCH
9 400 610 200
9400610200
ZEXEL
101601-3451
1016013451
KOMATSU
6138721311
6138721311
Rating:
Service parts 101601-3451 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
9 400 610 200
9400610200
ZEXEL
101601-3451
1016013451
KOMATSU
6138721311
6138721311
Zexel num
Bosch num
Firm num
Name
9 400 610 200
6138721311 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
B
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
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.5
1
2
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
3.2
2.7
3.7
Timer adjustment_05
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)Set the stopper bolt at speed = aa and rack position = bb.
(2)Normal
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)
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:
Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean.
Illustrations show fuel injection pump housing and governor removed from engine. Service work can be done with it installed on engine.1. Remove air bleed lines (2). 2. Remove bolts (1), flange (3), the flange assembly and the gaskets.3. Remove the bolts and the cover. 4. Remove bolts (5), solenoid (4) and the gasket.5. Remove two bolts (7) and fuel ratio control (6).6. Remove the shutoff housing from the cover. 7. Remove the bolts, lever (10) and shaft (8).8. Remove the bolts, lever (9) and shaft (11).9. Remove seal (12) from the shutoff housing. Install Shutoff Housing
1. Put 5S1454 Sealing Compound on the outside diameter of the seal and install the seal (1) with tooling (A) in the shutoff housing with the lip toward the outside. The outer face of the seal must be 1.0 mm (.039 in.) below the surface of the housing. Remove the extra sealing compound from the housing and the seal after installation. 2. Put shaft (5) in position in housing (4).3. Install lever (6) and the bolts. 4. Install shaft (2), lever (3) and the bolts. Make an alignment of the notch in shaft (2) with lever (3). 5. Put cover (7) in position on shutoff housing assembly (8) and install the bolts.6. Put fuel ratio control (10) in position and install the bolts. 7. Install the gasket, solenoid (9) and bolts on the cover.8. Put the cover in position and install the bolts.9. Install the gasket, flange assembly, gasket, flange (11) and the bolts.10. Connect air bleed lines (12).