Information injection-pump assembly
ZEXEL
101402-3810
1014023810

Rating:
Service parts 101402-3810 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
ZEXEL
101402-3810
1014023810
Zexel num
Bosch num
Firm num
Name
101402-3810
INJECTION-PUMP ASSEMBLY
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
Overflow valve
131424-3420
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.5
2.45
2.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 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
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
91.5
90.5
92.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
44
44
Boost pressure
mmHg
330
330
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.1+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder ON
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
90
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder OFF
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R1-0.25
Boost pressure
kPa
26
23.3
28.7
Boost pressure
mmHg
195
175
215
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1(9.7)
Boost pressure
kPa
30.7
30.7
30.7
Boost pressure
mmHg
230
230
230
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)The torque control spring does not operate.
(4)Adjust the secondary timing before adjusting the governor.
(5)RACK LIMIT (When hydraulic cylinder is OFF)
(6)Boost compensator stroke: BCL
(7)When hydraulic cylinder ON: P1
----------
K=15 BCL=0.25+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
----------
K=15 BCL=0.25+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=17deg+-3deg b=27deg+-5deg
----------
----------
a=17deg+-3deg b=27deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
----------
aa=15deg bb=0deg
----------
a=54deg54min+-3deg b=7deg30min+-30min
Information:
This Program must be administered as soon as possible. When reporting the repair, use "PI1324" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI1324" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Problem
The 1206437 and 1206438 Couplings used in the 1218021, 1218022, 1218023, and 1218024 Lines Group may slip off of the water piping during operation causing hot engine jacket water to escape from the jacket water circuit.Affected Product
Model & Identification Number
3606 (8RB571, 8RB588, 8RB589, 8RB599, 8RB600, 8RB610, 8RB614-617, 8RB631, 8RB632, 8RB634 , 8RB635)
3608 (6MC489-499, 6MC511, 6MC517, 6MC519, 6MC529)
3612 (9RC167, 9RC168, 9RC185, 9RC187, 9RC190, 9RC192, 9RC199, 9RC201-203, 9RC205, 9RC209-211 , 9RC213, 9RC217, 9RC223)
3616 (1PD184, 1PD198-205, 1PD207-211, 1PD223, 1PD224, 1PD226-231, 1PD237, 1PD238, 1PD245-248 , 1PD250, 1PD254-259, 1PD267, 1PD268)
Parts Needed
4 - 3E7424 Clamp4 - 1242732 Clamp1 - 1378788 Connector1 - 1378789 Connector1 - 1389817 Tube1 - 1389818 TubeAction Required
See attached rework procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Procedure: Jacket Water Pump Inlet Connector - Illustration 1
1. Remove the old 1206437 Coupling.2. Measure the gap between the tube ends.If the dimension is within tolerance (104 10 mm) then skip to Step 4. If the tube is not within tolerance, it will need to be removed and either lengthened, or shortened, using the tube provided.3. If lengthening the tube, cut the tube far enough away from the expanded end that the 1389817 Extension will not extend past the taper inside the tube. If shortening the tube, cut and remove a section from the tube of appropriate length, and rejoin the tube by welding the 1389817 Extension between the two halves.4. Install the new 1378788 Coupling. Note that the short end of the coupling goes on the pump side. Tighten the 1242732 Hose Clamps to
Problem
The 1206437 and 1206438 Couplings used in the 1218021, 1218022, 1218023, and 1218024 Lines Group may slip off of the water piping during operation causing hot engine jacket water to escape from the jacket water circuit.Affected Product
Model & Identification Number
3606 (8RB571, 8RB588, 8RB589, 8RB599, 8RB600, 8RB610, 8RB614-617, 8RB631, 8RB632, 8RB634 , 8RB635)
3608 (6MC489-499, 6MC511, 6MC517, 6MC519, 6MC529)
3612 (9RC167, 9RC168, 9RC185, 9RC187, 9RC190, 9RC192, 9RC199, 9RC201-203, 9RC205, 9RC209-211 , 9RC213, 9RC217, 9RC223)
3616 (1PD184, 1PD198-205, 1PD207-211, 1PD223, 1PD224, 1PD226-231, 1PD237, 1PD238, 1PD245-248 , 1PD250, 1PD254-259, 1PD267, 1PD268)
Parts Needed
4 - 3E7424 Clamp4 - 1242732 Clamp1 - 1378788 Connector1 - 1378789 Connector1 - 1389817 Tube1 - 1389818 TubeAction Required
See attached rework procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Procedure: Jacket Water Pump Inlet Connector - Illustration 1
1. Remove the old 1206437 Coupling.2. Measure the gap between the tube ends.If the dimension is within tolerance (104 10 mm) then skip to Step 4. If the tube is not within tolerance, it will need to be removed and either lengthened, or shortened, using the tube provided.3. If lengthening the tube, cut the tube far enough away from the expanded end that the 1389817 Extension will not extend past the taper inside the tube. If shortening the tube, cut and remove a section from the tube of appropriate length, and rejoin the tube by welding the 1389817 Extension between the two halves.4. Install the new 1378788 Coupling. Note that the short end of the coupling goes on the pump side. Tighten the 1242732 Hose Clamps to
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Komatsu
101402-3810
INJECTION-PUMP ASSEMBLY