Information injection-pump assembly
BOSCH
9 400 616 093
9400616093
ZEXEL
101695-3110
1016953110
KOMATSU
6207711960
6207711960
Rating:
Service parts 101695-3110 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 093
9400616093
ZEXEL
101695-3110
1016953110
KOMATSU
6207711960
6207711960
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
3.6
3.55
3.65
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
11.4
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
54.7
53.7
55.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.5+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=8 RAL=15+0.2mm N1=1250r/min N2=800r/min N3=1250r/min N4=400r/min
----------
----------
K=8 RAL=15+0.2mm N1=1250r/min N2=800r/min N3=1250r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=10deg+-5deg b=32deg+-3deg c=29deg+-5deg
----------
----------
a=10deg+-5deg b=32deg+-3deg c=29deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
Do not disconnect any air lines until the air pressure is zero.
1. Loosen the bleed valves and release the air pressure in the air tanks.2. Drain the oil from the oil pan. 3. Remove two short bolts (1) and two longer bolts (3) from manifold (2) and the BrakeSaver housing. Remove manifold (2). Remove the O-ring seals from the manifold. 4. Remove oil temperature sensing unit (4) from the BrakeSaver control valve.5. Disconnect air line (5) and hose assembly (6) from the BrakeSaver control valve. 6. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve. 7. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve. 8. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is 22 kg (48 lb.).9. Remove elbow (13) from the BrakeSaver control valve. Remove the O-ring seals. The following steps are for installation of the BrakeSaver control valve.10. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals.11. Install the O-ring seals and elbow (13) on the BrakeSaver control valve.12. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (11) in position under the oil pan. Install bolts (12) that hold the BrakeSaver control valve to the oil pan.13. Install oil temperature sensing unit (4) in the BrakeSaver control valve.14. Connect air line (5) and hose assembly (6) to the BrakeSaver control valve.15. Install the O-ring seals on manifold (2). Install manifold (2) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing.16. Make sure the O-ring seals are in place on the oil lines, and install oil lines (9) and (10).17. Install retainer (8) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Pipe Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).18. Fill the engine with oil to the correct level. See the Maintenance Manual.Disassemble & Assemble BrakeSaver Control Valve
Start By:a. remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.
Covers (3) and (4) hold a spring under compression. To prevent possible personal injury from flying parts, hold covers (3) and (4) when the bolts are removed.
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the O-ring seals and sleeve (5). 7. Remove bolt (11), plate