Information injection-pump assembly
BOSCH
9 400 616 284
9400616284
ZEXEL
103662-2911
1036622911
KOMATSU
6162731751
6162731751
Rating:
Service parts 103662-2911 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6162-12-3403
12.
Open Pre:MPa(Kqf/cm2)
29.4{300}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 284
9400616284
ZEXEL
103662-2911
1036622911
KOMATSU
6162731751
6162731751
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Overflow valve
133424-0420
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
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
18.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
587
582
592
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.8+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
71.8
66.8
76.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Minimum - maximum speed specification
(2)Variable speed specification.
(3)Target notch: K
(4)RACK LIMIT: RAL
(5)Load lever stop (with the speed lever at full)
(6)Idle sub spring setting: L1.
(7)Set idle.
----------
K=(10) RAL=18.9+0.2mm L1=7.7-0.5mm
----------
----------
K=(10) RAL=18.9+0.2mm L1=7.7-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set speed at bb (setting at shipping).
----------
aa=750r/min bb=900r/min
----------
a=(10deg)+-5deg b=(20deg)+-5deg c=(40deg)+-5deg
----------
aa=750r/min bb=900r/min
----------
a=(10deg)+-5deg b=(20deg)+-5deg c=(40deg)+-5deg
0000000901
F:Full load
I:Idle
S:Stop
(1)The distance between the stopper bolt and the lever must be aa.
----------
aa=(0.8)mm
----------
a=24deg+-5deg b=(25deg)+-5deg c=40deg+-5deg
----------
aa=(0.8)mm
----------
a=24deg+-5deg b=(25deg)+-5deg c=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Start By:a. remove timing gear coverb. remove fuel injection pump housing and governor 1. Remove four bolts (2), plate (3) and idler gear (1). 2. If the camshaft is not going to be removed, use Tool (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use Tool (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 205° C (400° F) for no longer than three hours and install it on the camshaft.9. Use Tool (B) and install the bearing in the idler gear. Set the gear on the front face (face with the timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) on the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and governorb. install timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use Tool (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 205° C (400° F) for no longer than three hours and install it on the camshaft.9. Use Tool (B) and install the bearing in the idler gear. Set the gear on the front face (face with the timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) on the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and governorb. install timing gear cover