Information injection-pump assembly
BOSCH
9 400 610 212
9400610212
ZEXEL
101605-3140
1016053140
KOMATSU
6137721660
6137721660
Rating:
Service parts 101605-3140 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6137-12-3100
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Include in #1:
101605-3140
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-1152
as _
Cross reference number
BOSCH
9 400 610 212
9400610212
ZEXEL
101605-3140
1016053140
KOMATSU
6137721660
6137721660
Zexel num
Bosch num
Firm num
Name
9 400 610 212
6137721660 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D105 K 14BE INJECTION PUMP ASSY PE6A PE
S6D105 K 14BE INJECTION PUMP ASSY PE6A 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
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
11.5
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
104
103
105
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
10
8.5
11.5
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)Idle sub spring setting: L1.
(3)Rack difference between N = N1 and N = N2
----------
K=15 L1=6-0.5mm N1=800r/min N2=500r/min
----------
----------
K=15 L1=6-0.5mm N1=800r/min N2=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Set the pump speed at aa
(2)Set speed at bb (setting at shipping).
(3)After confirming stopping, set at idling for delivery.
(4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=13deg+-5deg b=32deg+-3deg c=8deg+-5deg d=33deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=13deg+-5deg b=32deg+-3deg c=8deg+-5deg d=33deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At shipping
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Information:
28. Remove ring (57) and dashpot assembly (58). 29. Use tool (C) to remove snap ring (64). Remove ring (63) and spool (62).30. Remove seat (61) from spring (60) and remove spring (60) from seat (59). 31. Remove spring (overfueling spring) (65) and riser (66). 32. Remove ring (67), races (68) and bearing (69). Make a replacement of shield (70) any time it is removed.33. Use a screwdriver to remove shield (70) as shown. 34. Remove bolts (71) and carrier (72). 35. Remove dowels (73) and flyweights (75).36. Remove shaft (74) and the dowel from shaft (74). 37. Remove races (76) and bearing (77).Assemble Governor
Put clean oil on all parts before assembly. Be sure all oil passages are clear. 1. Install one race (76), bearing (77) and the other race on the camshaft in the fuel injection pump housing. 2. Put flyweights (75) in position on carrier (72) and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in) end play. 3. Install dowel (78) in governor shaft (74) and install the governor shaft in the carrier as shown. 4. Put carrier (72) in position and install bolts (71). Make a replacement of shield (70) any time it is removed.5. Install shield (70) on the carrier and use tool (D) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 15° apart next to the holes in the shield. 6. Install race (68), bearing (69), race (68). Use tool (C) to install the ring on riser (66) as shown. 7. Install riser (66) and spring (overfueling spring) as shown. 8. Assemble the dashpot as follows:a. Install spring (60) on seat (59) and install seat (61) in spring (60).b. Put spool and ring (63) in position on seat (61) and use tool (C) to install snap ring (64). 9. Install dashpot assembly (58) as shown. 10. Install ring (57) in the lower groove in the governor shaft. Install sleeve (56), spring (54), sleeve (56) and bearing (55). Spring (54) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (B) to hold spring (54) in compression and install ring (53) in the groove in the governor shaft. Remove tool (B). 12. Put lever (52) in position on the governor servo and install pin (50) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90° apart on the outside surface on both legs of the governor servo to hold pin (50) in place.13. Install the O-ring seal on sleeve (49). Install piston (51) and sleeve (49) as shown.14. Install valve (44) as shown. 15. Install one lockring (48) in the groove near the center of valve (44). Put sleeve (45), spring (broken link spring) (46)
Put clean oil on all parts before assembly. Be sure all oil passages are clear. 1. Install one race (76), bearing (77) and the other race on the camshaft in the fuel injection pump housing. 2. Put flyweights (75) in position on carrier (72) and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in) end play. 3. Install dowel (78) in governor shaft (74) and install the governor shaft in the carrier as shown. 4. Put carrier (72) in position and install bolts (71). Make a replacement of shield (70) any time it is removed.5. Install shield (70) on the carrier and use tool (D) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 15° apart next to the holes in the shield. 6. Install race (68), bearing (69), race (68). Use tool (C) to install the ring on riser (66) as shown. 7. Install riser (66) and spring (overfueling spring) as shown. 8. Assemble the dashpot as follows:a. Install spring (60) on seat (59) and install seat (61) in spring (60).b. Put spool and ring (63) in position on seat (61) and use tool (C) to install snap ring (64). 9. Install dashpot assembly (58) as shown. 10. Install ring (57) in the lower groove in the governor shaft. Install sleeve (56), spring (54), sleeve (56) and bearing (55). Spring (54) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (B) to hold spring (54) in compression and install ring (53) in the groove in the governor shaft. Remove tool (B). 12. Put lever (52) in position on the governor servo and install pin (50) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90° apart on the outside surface on both legs of the governor servo to hold pin (50) in place.13. Install the O-ring seal on sleeve (49). Install piston (51) and sleeve (49) as shown.14. Install valve (44) as shown. 15. Install one lockring (48) in the groove near the center of valve (44). Put sleeve (45), spring (broken link spring) (46)