Information injection-pump assembly
BOSCH
9 400 616 377
9400616377
ZEXEL
103684-0370
1036840370
KOMATSU
6162741751
6162741751
Rating:
Service parts 103684-0370 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6162-14-3400
12.
Open Pre:MPa(Kqf/cm2)
29.4{300}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 377
9400616377
ZEXEL
103684-0370
1036840370
KOMATSU
6162741751
6162741751
Zexel num
Bosch num
Firm num
Name
9 400 616 377
6162741751 KOMATSU
INJECTION-PUMP ASSEMBLY
SAA6D170 K 14BS INJECTION PUMP ASSY PE4-8Z PE
SAA6D170 K 14BS INJECTION PUMP ASSY PE4-8Z 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
105780-8130
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
131425-1620
Overflow valve opening pressure
kPa
255
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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
2.95
3.05
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
-
Rack position
16.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
702
695
709
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
40.5
38.5
42.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
16.9+0.2
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
580
540
620
Fixing the rack
*
Rack limit
*
Test data Ex:
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(65deg)
----------
----------
a=(65deg)
Information:
Tooling and Equipment
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.
The tools shown in Chart F, Tooling for Finding Top Center (TC) Position, are required to complete the procedure.
Table 8
Chart F
Tooling For Finding Top Center (TC) Position
Part No Description Qty Item (1)
8T-4177 Bolt, Spring Compressor 1 7
( 1 ) Refer to the nomenclature chart at the beginning of this manual for item identification.Procedure
Illustration 39 g03425683
Timing Bolt Location (35) 8T-4177 Timing Bolt (36) Timing Hole (37) Flywheel HousingNote: Depending on engine application, timing hole (36) is located at either the left front face or the right front face of the flywheel housing.
Remove plug from the timing hole (36) on the front of the flywheel housing.
Rotate the engine with four large bolts on the front of the crankshaft. Do not use the eight small bolts on the front of the crankshaft pulley as this could cause damage to the engine.
Put 8T-4177 Bolt (35) in hole. Turn the engine flywheel counterclockwise until the timing bolt engages with the threaded hole in the flywheel.Note: If the flywheel is turned beyond the point the timing bolt engages in the threaded hole, the flywheel must be turned back at least 30 degrees clockwise. Again, turn the flywheel counterclockwise until the timing bolt engages with the threaded hole. This procedure makes sure that the play is removed from the gears when number 1 piston is put on TC.
Remove the cylinder head valve cover.
Illustration 40 g03425694
Valve Cover Removed
The intake and the exhaust valves for the number 1 cylinder are fully closed if number 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms cannot be moved and the valves are slightly open, the number 1 piston is on the exhaust strike. Refer to Chart E, Crankshaft Positions for Fuel Timing Settings, to determine which cylinders can be checked/adjusted (determined by stroke position of crankshaft when timing bolt is installed).Note: When the actual stroke position is identified, and the other stroke position is desired, it is necessary to remove the timing bolt from the flywheel. Turn the flywheel counterclockwise 360 degrees, and reinstall the timing bolt.
After TC position for a particular stroke is obtained and adjustments are made, remove the timing bolt and turn the flywheel counterclockwise 360 degrees. This will put number 1 piston at TC position on the other stroke. Install timing bolt in the flywheel and complete adjustments for remaining cylinders.Removal and Installation of Unit Fuel Injectors
Table 9
Chart G
Injector Removal and Installation Tools
Part No Description Qty Item (1)
5P-0302 Injector Removal Bar 1 16
194-3542 Hex Socket Bit Driver, 5 mm 1 18
( 1 ) Refer to nomenclature chart, at the beginning of this manual for item identification.
Illustration 41 g03425701
Unit Fuel Injector (48) Bolt (49) O-RingsNote: Not all injectors use a bottom O-ring.Removal
Remove injector hold down bolt (48) .
Do not pry on the injector hold down bracket.