Information injection-pump assembly
ZEXEL
103662-3101
1036623101
KOMATSU
6162731571
6162731571
Rating:
Service parts 103662-3101 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6162-13-3902
12.
Open Pre:MPa(Kqf/cm2)
29.4{300}
15.
NOZZLE SET
Cross reference number
ZEXEL
103662-3101
1036623101
KOMATSU
6162731571
6162731571
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
131425-2020
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
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
16.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
473
468
478
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.2+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
49
45
53
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
18
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
482
477
487
Fixing the lever
*
Boost pressure
kPa
50.7
50.7
Boost pressure
mmHg
380
380
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
14
Boost pressure
kPa
9.3
9.3
9.3
Boost pressure
mmHg
70
70
70
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
18
Boost pressure
kPa
41.3
38.6
44
Boost pressure
mmHg
310
290
330
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch: K
(2)RACK LIMIT: RAL
(3)Boost compensator stroke: BCL
(4)Rack difference between N = N1 and N = N2
----------
K=11 RAL=20+0.2mm BCL=4+-0.1mm N1=1000r/min N2=700r/min
----------
----------
K=11 RAL=20+0.2mm BCL=4+-0.1mm N1=1000r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=38deg+-5deg
----------
----------
a=18deg+-5deg b=38deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)The clearance from the set screw must be aa.
(2)Set screw at speed = bb, rack position = cc.
(3)Use the pin above R = dd
----------
aa=2+1mm bb=100r/min cc=5mm dd=44mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=2+1mm bb=100r/min cc=5mm dd=44mm
----------
a=20deg+-5deg b=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:
1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Separate cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), the seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip-type seals and the bottom bearing from pump body (2).8. Remove check valve (13).Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must be .80 .50 mm (.031 .020 in) below the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 26.19 .13 mm (1.031 .005 in) from the bottom (drive gear) surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.559 .020 in) from the bottom (drive gear) surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the bottom (drive gear) surface of the pump body. 6. Heat gear (8) to a maximum temperature of 315° C (600° F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 .010 in).7. Install the drive shaft and gear in body (3). Install the key, gear (10) and nut (9). Tighten the nut to a torque of 30 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 22.61 .05 mm (.890 .002 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15) and seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 37 4 N m (27 3 lb ft).
Do not let the liquid gasket enter the pump during application or assembly.
11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3). The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the tachometer drive on cover (1).End By:a. install fuel transfer pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must be .80 .50 mm (.031 .020 in) below the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 26.19 .13 mm (1.031 .005 in) from the bottom (drive gear) surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.559 .020 in) from the bottom (drive gear) surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the bottom (drive gear) surface of the pump body. 6. Heat gear (8) to a maximum temperature of 315° C (600° F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 .010 in).7. Install the drive shaft and gear in body (3). Install the key, gear (10) and nut (9). Tighten the nut to a torque of 30 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 22.61 .05 mm (.890 .002 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15) and seal and plug (13) in pump cover (1). Tighten plug (13) to a torque of 37 4 N m (27 3 lb ft).
Do not let the liquid gasket enter the pump during application or assembly.
11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body (3). The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install the tachometer drive on cover (1).End By:a. install fuel transfer pump