Q —. O01 GENERAL SSS ‘SPECIFICATIONS GENERAL VIEW FIPPOO 01-001SPECIFICATIONS Machine model HD785-3, HD985-3 Engine model SA12V140-1 (Mounts 2 fuel injection pumps) Fuel injection pump type KFE6S135R-1 Dimensions (length x width x height) mm 526 x 139 x 320 Weight kg 30.0 (Not including flyweight) ** Direction of rotation Clockwise Fling order 1-5-9-6-2-4 Injection interval oo #20" Plunger diameter io 135 Cam it plunger stoke) a 135 Prestroke *2 mm 4-6 Delivery valve cracking pressure | MS 3 {eit Pe dotvony van 2 PreeeU| MES, G00. J mmst. Delivery valve retraction volume * FIPPOO “1: The flyweight mentioned here is the small fly- weight connecting the fuel injection pump and the engine. #2: With this pump, the prestroke automatically varies within the range shown in the chart. (This is called the prestroke control and is a special function ofthe fuel injection pump with electronic governor.) #3: The delivery valve on this pump is an equal Pressure type, so it differs from the normal ‘equal volume type, so it does not have a re- traction function. However, the ability to stop the flow of fuel after the completion of injec- tion is good in the same way as the equal volume type. 01-002FIPPOO HO465-5 0465-5 WA700-1 PC1100-6 SAGD170-A-1 ‘SAAGD170E-2 KFE6S135L-4 526 x 139x320, 30.0 (Not including flyweight) * Left 1-5-3-6-2-4 60" +20" 135 135 35-55 33-53 170 117.3) ‘9.80 £100) FUEL INJECTION PUMP MODEL The model of fuel injection pump is marked on the name plate as follows. KFE 6 S$ 195 R-1 Number of cylinders > Plunger diameter (mm) x 10 >R: Rotates to right, L: Rotates to left —> This indicates that it is a Komatsu fuel injection pump. » S: shows that it is equipped with an electronic governor and has a variable prestroke ‘—+ This indicates the version (number of design upgrade) 01-003GENERAL VIEW VIEW FROM LEFT SIDE 01-004 ¥E01087 FIPPOOVIEW FROM RIGHT SIDE Fuel (to nozzle) tttttt Fual return ‘to tust tank) Fast intet sort, Cites! Hite > Bl _— “FAA 2 oO a FIPPOO > 1 iniet sort Lubricating oll osttet sort ‘euin'eallers) (te eneine ofl sant swe01058 01-005VIEW FROM FRONT 01-006 block To evtinger S¥EO1059 FIPPOOFIPPOO VIEW FROM REAR KFE6S135R-1 KFE6S135L-1 Rear view ' ' u 4 i 1 o 8 sveoones r sveoosne 1 Fuel pump Hydraulic pump 2 Hydraulic pump Fuel pump 3 Fuel outlet port Blind 4 Fuel inlet port Hydraulic filter 5 Hydraulic filter Fuel inlet port 6 Blind Fuel outlet port 7 Hydraulic relief valve 8 Lubricating oil inlet port Hydraulic relief valve Note: The above diagram applies to 6-cylinder engines. For the V-type 12-cylinder engine, the cylinders are divided into the right bank and left bank, so the position of all parts is different from the diagram above. 01-007‘SEBM012700 SHOP MANUAL FUEL INJECTION PUMP (With KOMATSU ELECTRONIC GOVERNOR) FUEL INJECTION PUMP MODEL KFE 00-001CONTENTS 01 GENERAL... 11 STRUCTURE AND FUNCTION .. 12, TESTING AND ADJUSTING .. 13 DISASSEMBLY AND ASSEMBLY .... 14 MAINTENANCE STANDARD . 15 OTHERS ... 00-002 FIPPOO—_-. 11 STRUCTURE AND FUNCTION — ‘STRUCTURE... FUNCTION ose FIPPOO 11-001STRUCTURE Fuel injection pump body Rack position control hydraulic cylinder Prestroke control solenoid Rack position control solenoid Pump (hydraulic pump, fuel pump) Rack position sensor Rack position sensor circuit NOM aeNs 11-002 E00987, FIPPOOHYDRAULIC CIRCUIT g swe00908 1. Hydraulic pump 2. Relief valve (1.5 MPa {15 kg/em’}) 3. Filter 4, Rack position control hydraulic valve 4-1,Rack position control solenoid 5. Rack position control hydraulic cylinder 6._ Prestroke contro! hydraulic valve 6-1.Prestroke control solenoid 7. Prestroke control hydraulic cylinder 8. Hydraulic fitter 9. Komatsu fuel injection pump with electronic governor 11-003FUEL CIRCUIT FIPPOO S¥E00969, 1. Priming pump {installed to part other than fuel injection pump) 2. Feed pump 3. Bypass valve 4. Relief valve (0.3 MPa (3 kg/em’)) 5. Filter 6. Fuel gallery 7. Plunger and plunger barrel 8. Overflow valve 9. Komatsu fuel injection pump with electronic governor O 10. Fuel tank 11-004FIPPOO ELECTRICAL CIRCUIT Controtter Chassis wiring harness ae Ley fuel Indection oune a ee % Conoctor (aule svare connector) fie Rack sosition ee, Contral solenoid J e*4 Conector G-vin, mate) Ho) ae} i j ae Prestroke control solenoid | Comector G-via, sale) Yenarked connector o785-3 | 40326-6 HDgB5-3 | HD485-5 A700, PC1 100-6 None 3p S¥E01080 11-005EXPLODED VIEW 00D =o CHa GOD 3 8 4 g E 8 9 | i 1. Dativory valve M built-in equal pressure valve) 2. Plunger barrel 3. Plunger 4. Rack 5. Roller tappet © 11-006FIPPOO PeNe 5 sE00992 |. Housing (C) . Camshaft . Flyweight 1. Rack position sensor 11-0071. Housing (A) 2. Prestroke control hydraulic valve 3. Rack position control hydraulic valve 4. ing (B) 11-008 FIPPOOFIPPOO NOQEeNe Rack position control solenoid . Prestroke control solenoid Hydraulic filter Plate Body . Hydraulic relief valve . Oil inlet port @weo emo/ €& sweooan4 11-009OIL PASSAGE [Hydraulic pump ~ prestroke control hydraulic valve and rack position control hydraulic valve ] Plate ou tiiter Back sosition control hydrautie valve sve01081 11-010 FIPPOOOIL PASSAGE [Rack position control hydraulic valve ~+ rack position control hydraulic cylinder } Rack sosition contrat Rydratiiec evtinder ' views Back sosition i Hougine FIPPOO Rack sosition contra! Rrarautie valye View sveoi082 11-011OIL PASSAGE [ Prestroke control hydraulic valve ~ oil gallery of housing (C) } Housing Housine (@) Hovsing (o (HI | i \ See Pc cone | Lo LOOOC0O ‘ Cross section a 301063 11-012FUEL PASSAGE O0dals 11-013CROSS-SECTIONAL DIAGRAM [Fuel injection pump } 11-014 swe00908 FIPPOO[ Fuel injection pump } sMe01000 FIPPOO [Rack position control cylinder ] CL Lill VVCVOC ‘¥E01001 11-015[Hydraulic pump (for KFE6S135L-1) ] =p een Feliet ‘sive —— e—— ( . ») « : = . oe | e-E on ran & Filter 1 8 Reliet mie i e-c ain S¥E01088, © 11-016FIPPOO [Hydraulic pump (for KFE6S135R-1) | E-E Fue) D-p win y 11-017[ Relief valve (for HD785-3, HD985-3) | SHE01 004 [ Relief valve (for all machines except above) ] z a ‘5¥E01005 11-018[ Plunger barrel and plunger ] FIPPOO Prestrote contrat hvdrautte evi tage Pioneer valve Planser ‘50601085 11-019[ Delivery valve and equal pressure valve } Oodals 11-020[Solenoid } Coit FIPPOO \ 45202 Tolat stroke Detail P ‘svE01087 11-021[Rack position sensor ] O0dals sweo1088 O 11-022FIPPOO OPERATION Function of governor Mechanical governor Electronic governor Basic function of governor Basic functions are governed by all component parts inside me- chanical governor (fiyweight, lever, spring, etc.) Note’:For detalis of the me- chanical governor, see “COMPONENT OF ENGINE” (No. SEBECOMPOd3), ‘The basic functions are governed by the rack Position control system (rack position con- trol cylinder, rack position control valve, rack Position control solenoid built into electronic ‘governor, and rack position sensor, and con- troller outside electronic governor). Function to know when engine has started It is known that the engine has started, from the spring inside the mechanical governor. The electric signal from the starting ewitch asses through the wiring harness and in- forms the controller that the engine has started. Function to know angle of ac- celerator pedal ‘This is known from the angle of the speed control lever installed to the mechanical governor. This is known from the angle sensor installed to the accelerator pedal. Function to know engine speed This is known from the fly- weight inside the mechanical governor. This is known from the engine speed sensor installed to the engine flywheel housing, Function to advance fuel injec- tion timing according to rise in ‘engine speed The timer governs this function This function is governed by the prestroke control system (prestroke control cylinder, prestroke control valve and prestroke control solenoid inside electronic governor, and con- troller and engine speed sensor outside elec- tronic governon). Funetion to know rack position This is known from the rack position sensor. 11-023RACK POSITION CONTROL SYSTEM Rack osition conteot evtin aN Z —_I lexciusive tor alectronle soversor) | | contrat ter Rack bosition antral valve NN tte Electric etenst Enein ens Uinstatted to flvehee! hoesiae) Note : “Q” and “R” are both connected on the circumference. 11-024 Arete sensor Unstalled to accelerator oedstd sweoross FIPPOO& = Operation of rack position control system 1) The controller knows the speed desired by the operator from the electric signal (output volt- age) from the angle sensor installed to the accelerator pedal. To obtain the desired speed, it selects the necessary rack position from the data already stored in the control- ler memory. It then selects the value for the solenoid current that matches the rack posi- tion from the data and sends the current to the rack position control solenoid. (The above explanation shows the concept of the system. In fact, it determines the sole- noid current directly from the voltage output from the angle sensor on the pedal.) 2) When the solenoid pushes the rack position control valve spool, it pushes the spring in- side the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reac- tion force of the spring. The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion P are also proportional. Solenoid current bushing force 3) The oil pressure at portion P passes through the oil passage and is transmitted to the rack position control cylinder. It pushes the spring inside the cylinder and compresses it to move the piston. It stops at the point where the hydraulic pressure at portion P is balanced with the reaction force of the spring. The hydraulic force at portion P and the change in the position of the piston are pro- portional. The change in the position of the piston means the change in the position of the rack. By controlling the solenoid current, the rack position is controlled indirectly. 4) The controller knows if the rack position is being correctly controlled from the rack posi- tion sensor. Ifthe rack position is not correct, it corrects it. 5) The amount of fuel injected corresponds to the position of the rack. If any load is applied to the engine, the con- troller knows that the engine speed has dropped from the engine speed sensor, so it controls the position of the rack to increase the injection volume and prevents the engine speed from going down. Ftion (mm) ack 9 0 0.418 0.682 Soles ° 2025 ack position (ma) sycoiorp 11-025PRESTROKE CONTROL SYSTEM NV a \ Prestroke controt olinger contrat Serine Hyarditic pone oll Note 1 : "Z” and *X” are both connected on the circumference. Note 2 : The plunger normally consists of one Part, but with the fuel injection pump for the electronic governor, the plunger con- sists of two parts (top and bottom). 11-026 s¥e01071 There is a spring between the top part id the bottom part, so the hydraulic jer consists of these three parts. is the prestroke control cylinder, and the prestroke is changed by changing the length of the plunger. FIPPOO oOFIPPOO Operation of prestroke control system 1) The controller knows the engine speed from the electric signal from the engine speed sen- sor. Itelects the matching value for the angle of advance suitable to the engine speed from the data already stored in the controller memory, then selects the value for the prestroke that matches the angle of advance from the data, and then selects the value for the solenoid current that matches the value of the prestroke from the data, and sends the current o the prestroke control solenoid. (The above explanation shows the concept of the system. In fact, it determines the solenoid current directly from the engine speed.) 2) By controlling the solenoid current, the prestroke is controlled indirectly, and as a re- sult it controls the angle of advance. The current flowing to the solenoid and the solenoid pushing force are proportional. ‘When the solenoid pushes the prestroke con- trol valve spool, it pushes the spring inside the valve and compresses it to move the spool. The solenoid stops at the point where the pushing force is balanced with the reac- tion force of the spring. 755" Anse of advance 3) 0 tari ss om Solenoid current The solenoid pushing force and the change in the position of the spool are proportional. The change in the position of the spool and the hydraulic pressure at portion Y are also proportional. The hydraulic force at portion Y passes through the oil passage circuit and is trans- mitted to the prestroke control cylinder inside the plunger. It pushes and compresses the spring inside the plunger, pushes up the top part of the plunger, and extends to increase the length of the plunger until the hydraulic force and spring force are balanced. The prestroke becomes shorter by the amount that the plunger becomes longer. The fuel injection timing is advanced by the ‘amount that the prestroke becomes shorter. That is, the injection angle is advanced. As a result of the flow of controls described above, if the engine speed is changed, the angle of advance is changed as shown in the charts below. tar ! Saat baste of advance Ensine sveed sveoto72 11-027