Information injection-pump assembly
ZEXEL
101605-3150
1016053150
KOMATSU
6138721870
6138721870
Rating:
Service parts 101605-3150 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6138-12-3200
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101605-3150
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
101605-3150
1016053150
KOMATSU
6138721870
6138721870
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
Overflow valve
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
113.3
112.3
114.3
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
375
375
375
Average injection quantity
mm3/st.
13.5
13.5
13.5
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.7+-0.5
Pump speed
r/min
775
775
775
Average injection quantity
mm3/st.
20
18.8
21.2
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.
----------
K=15 L1=7-0.5mm
----------
----------
K=15 L1=7-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Speed = bb (at shipping)
(3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=6deg+-5deg c=24deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=6deg+-5deg c=24deg+-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:
Start By:a. remove governor **See Disassemble Governor story
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the bolts and the plate from the side of the fuel injection pump housing. 2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position to remove the fuel injection pumps.3. Use tool (B) to remove bushing (1).4. Remove the O-ring seal from the fuel injection pump housing. 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (2). Keep the spacers (2) from the fuel injection pumps together with identification as to their location in the pump housing.7. Perform steps 3 through 6 to remove the other fuel injection pumps. The following steps are to install the fuel injection pumps.8. Install spacer (2).9. Install tool (A). Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.10. Turn camshaft until the lobe of the camshaft is down for the pump to be installed.11. Install tool (C) on the bonnet on the fuel injection pump.12. Install the fuel injection pump in the pump housing with saw cut slot in the gear in alignment with the small pin and groove in the barrel in alignment with dowel in the pump housing.13. Put clean oil on O-ring seal and install it in the fuel injection pump housing.14. Install the bushing by hand until the bushing is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump ad put the pump in alignment again and install the bushing again.15. Install tool (B) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft).16. Install tooling (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of improper fuel injection pump installation.17. Perform Steps 1 through 9 to install the other fuel pumps18. Install the cover and gasket on the fuel injection pump housing.End By:a. install governor **See Assemble Governor storyDisassemble And Assemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
When the injection pumps are disassembled, handle the parts carefully. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not intermix the plunger of one pump in the barrel with another pump. If one part is worn, install a complete new pump assembly. Be careful when placing the plunger into the bore of the barrel.
1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).
Do not remove the gear from
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the bolts and the plate from the side of the fuel injection pump housing. 2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position to remove the fuel injection pumps.3. Use tool (B) to remove bushing (1).4. Remove the O-ring seal from the fuel injection pump housing. 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (2). Keep the spacers (2) from the fuel injection pumps together with identification as to their location in the pump housing.7. Perform steps 3 through 6 to remove the other fuel injection pumps. The following steps are to install the fuel injection pumps.8. Install spacer (2).9. Install tool (A). Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.10. Turn camshaft until the lobe of the camshaft is down for the pump to be installed.11. Install tool (C) on the bonnet on the fuel injection pump.12. Install the fuel injection pump in the pump housing with saw cut slot in the gear in alignment with the small pin and groove in the barrel in alignment with dowel in the pump housing.13. Put clean oil on O-ring seal and install it in the fuel injection pump housing.14. Install the bushing by hand until the bushing is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump ad put the pump in alignment again and install the bushing again.15. Install tool (B) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft).16. Install tooling (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of improper fuel injection pump installation.17. Perform Steps 1 through 9 to install the other fuel pumps18. Install the cover and gasket on the fuel injection pump housing.End By:a. install governor **See Assemble Governor storyDisassemble And Assemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
When the injection pumps are disassembled, handle the parts carefully. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not intermix the plunger of one pump in the barrel with another pump. If one part is worn, install a complete new pump assembly. Be careful when placing the plunger into the bore of the barrel.
1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).
Do not remove the gear from