Information injection-pump assembly
ZEXEL
101402-3451
1014023451
KOMATSU
6131721211
6131721211
Rating:
Service parts 101402-3451 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6137-12-3100
12.
Open Pre:MPa(Kqf/cm2)
22.1{225}
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-3451
1014023451
KOMATSU
6131721211
6131721211
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
1-2-4-3
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
85
83
87
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
83
83
88
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
4.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
10
8
12
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
----------
K=10
----------
----------
K=10
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=11deg+-5deg b=32deg+-3deg c=32deg+-5deg
----------
----------
a=11deg+-5deg b=32deg+-3deg c=32deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of center of spline's wide tooth at No 1 cylinder's beginning of injection (key position)
(3)B.T.D.C.: aa
(4)-
----------
aa=21deg
----------
a=(30deg)
----------
aa=21deg
----------
a=(30deg)
Information:
Introduction
The problem that is identified below has a known solution. Use the solution that is identified below.Problem
The procedure for the Disassembly and Assembly needs to be updated to include the information below.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Inspect the quill tubes and fuel injectors for cuts or marks at the mating surfaces.
Replace any quill tubes since the quill tubes are a one time use component. Replace the copper washer when replacing the fuel injector.
Follow the steps below for installing the quill tunes and fuel injectors.
Seat the injector by installing and torquing the injector hold down clamp bolt to 30 3 N m (22 2 lb ft).
Install the quill tube and tighten the quill nut between 15 N m (11 lb ft) to 20 N m (15 lb ft).
Apply a final torque of 30 3 N m (22 2 lb ft) to the injector hold down clamp bolt.
Apply a final torque between 50 N m (37 lb ft) to 55 N m (41 lb ft).
The problem that is identified below has a known solution. Use the solution that is identified below.Problem
The procedure for the Disassembly and Assembly needs to be updated to include the information below.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Inspect the quill tubes and fuel injectors for cuts or marks at the mating surfaces.
Replace any quill tubes since the quill tubes are a one time use component. Replace the copper washer when replacing the fuel injector.
Follow the steps below for installing the quill tunes and fuel injectors.
Seat the injector by installing and torquing the injector hold down clamp bolt to 30 3 N m (22 2 lb ft).
Install the quill tube and tighten the quill nut between 15 N m (11 lb ft) to 20 N m (15 lb ft).
Apply a final torque of 30 3 N m (22 2 lb ft) to the injector hold down clamp bolt.
Apply a final torque between 50 N m (37 lb ft) to 55 N m (41 lb ft).