Information injection-pump assembly
BOSCH
9 400 612 198
9400612198
ZEXEL
101602-3420
1016023420
KOMATSU
6136721100
6136721100
Rating:
Service parts 101602-3420 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6136-12-3100
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 612 198
9400612198
ZEXEL
101602-3420
1016023420
KOMATSU
6136721100
6136721100
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
1-5-3-6-
2-4
Pre-stroke
mm
3.3
3.25
3.35
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
8.2
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
34.5
33.5
35.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
9.5
8.5
10.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Rack difference between N = N1 and N = N2
(3)Rack difference between N = N3 and N = N4
----------
K=7 N1=1250r/min N2=800r/min N3=1250r/min N4=400r/min
----------
----------
K=7 N1=1250r/min N2=800r/min N3=1250r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=6deg+-5deg b=21deg+-5deg c=32deg+-3deg
----------
----------
a=6deg+-5deg b=21deg+-5deg c=32deg+-3deg
0000001501 LEVER
(F) P/N: Part number of the shim
L1:Thickness (mm)
1. Adjustment of the control lever
(1)Perform idling with the control lever (A) contacting the pushrod (B). At this time, confirm that the spring (C) is not compressed by control lever (A)'s operating torque.
(2)To set the stop position, compress spring (C) using the control lever (A) and adjust the rack so that it contacts the guide screw (D) at position L2. Then, set and fix using the lock nut (E). Adjust the rack position L2 at this time using the shim (F).
(3)Confirm that the control lever (A) returns to the idling position when pulled in the stop direction and then released.
----------
L2=0.2~2mm
----------
----------
L2=0.2~2mm
----------
Information:
Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Reference Section
Refer to Service Magazine, M0082326, "Diesel Exhaust Fluid (DEF) Contamination on C4.4 Machine Engines".Refer to Service Magazine, M0096547, "Diesel Exhaust Fluid (DEF) Pump Filter Maintenance on Certain C4.4 Machine Engines".Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".Problem
There have been instances of returned DEF pumps that have no fault found or indicating contamination.Resolution
Complete the form below and attach to any SIMSi claim in addition to a Product Status Report (PSR) from before any troubleshooting was performed or any diagnostic codes were cleared.
Use the electronic service tool to download a PSR with Histograms.
Enter the diagnostic codes that require troubleshooting: ___
Perform the correct troubleshooting procedure for any active diagnostic codes. Refer to Troubleshooting, Diagnostic Trouble Codes.
If the troubleshooting procedure requests that the DEF is tested for contamination or concentration , record the results in Table 1 and Table 2.
For other DEF-related troubleshooting procedures, follow the applicable troubleshooting steps and record the results in Table 3.
Table 1
DEF Contamination
Step Instruction Completed Result Units
1 Perform the test procedure for DEF contamination. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test.
2 Compensator measurements. Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".
Diameter (A) mm
Length (B) mm
3 If contamination is present, confirm that DEF system has been flushed. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush
Table 2
DEF Concentration
Step Instruction Completed Result Units
1 Perform the test procedure for DEF concentration. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test. %
2 If the DEF concentration is out of specification, confirm that the DEF tank has been drained and filled with the correct specification of DEF. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid - Fill.
Table 3
DEF Troubleshooting
Step Instruction Completed Result Units
1 Latest engine and Dosing Control Unit (DCU) software has been installed. Refer to Troubleshooting, ECM Software - Install.
2 DEF lines have been checked for restrictions.
3 DEF pump has been checked for restrictions.
4 DEF injector has been checked for restrictions.
5 DEF lines have been inspected for leaks.
6 Confirm the DEF pressure. Refer to Troubleshooting, DEF Pressure Does Not Respond. kPa
7 DEF dosing system accuracy test has been performed. Refer to Troubleshooting, Aftertreatment SCR System Dosing - Test.
8 DEF pump filter replaced.
9 "Aftertreatment System Functional Test" performed. Refer to Troubleshooting, Service Tool Features.