Information injection-pump assembly
ZEXEL
101402-3880
1014023880
KOMATSU
6732711121
6732711121
Rating:
Service parts 101402-3880 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
101402-3880
1014023880
KOMATSU
6732711121
6732711121
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
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
9.4
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
90
89
91
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.1+-0.5
Pump speed
r/min
465
465
465
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
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
*
Rack limit
*
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
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Speed = aa (active mode)
(2)-
(3)Speed = bb (normal mode)
(4)At hole above R = cc (center)
----------
aa=1155r/min bb=1050r/min cc=80mm
----------
a=14deg+-3deg b=33deg+-5deg c=32deg+-3deg d=5deg+-5deg
----------
aa=1155r/min bb=1050r/min cc=80mm
----------
a=14deg+-3deg b=33deg+-5deg c=32deg+-3deg d=5deg+-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=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
Information:
(1) Nut (4K0367)(2) Bearing (9U6877)(3) Washer (5P8247)(4) Bridge plate (9U7259)(5) Bolts (5/16)(6) Threaded rod puller stud (221-9778)(7) Threaded end
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and
Install the remaining parts of Tool B on the threadedrod assembly (item 6).
Lubricate the threads on (item 6).
Tighten nut (item 1) in order to remove the unitinjector sleeve. Do not use an impact wrench.
After the sleeve is removed, use the large 4C5552wire brush to remove dirt and sealant from the bore. Squirt isopropyl alcoholor brake cleaner into the bore to remove oil. Use paper towels and swabsto remove all debris from the bore. Ensure the injector bore and fuel railare clean and free from debris.
Any sealant, fuel, oil or debris willprevent the sealant from properly curing. Improper cleaning will lead toa poor sealing surface and leak path.
Table 3 Unit Injector Sleeve ? InstallRequired Tools
ToolA
Part Number Description Quantity
2219777 Sleeve Installer 1
4C9507 Locktite 620 Sealant 1 Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure the o-ring (8T7878) is in place on the2219777 sleeve installer
Place the 1785037 unit injector sleeve on ToolA.
Clean the sleeve with isopropyl alcohol and wipedry with as clean paper towel. Note: Make sure the sleeve is free ofall debris, oil and fuel.
Apply 4C9507 Locktite 620 sealant (shake wellbefore using, sealant can separate) to the upper land and lower land ofthe unit injector sleeve.
Surfaces to be sealed must be freeof oil, grease, fuel, etc.
Install the unit injector sleeve into the injectorsleeve bore.
Use a hammer to drive the sleeve into the headuntil the sleeve bottoms out.
Wipe all excess anaerobic from the injector borewith a paper towel and swab.
Stamp AH on the front left top of the cylinderhead near the HEP 8 pump to verify the rework has been completed.
Wait approximately two (2) hours atroom temperature (70F) before filling the engine with fuel or coolant.Longer curing time is needed at lower temperatures.Unit injectors ? Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Part Number Description Quantity
Tool A 1492955 Seal Protector 1
Tool B 1492956 Seal Installer 1
Install injection actuation pressure sensor. Torquethe sensor to 10 2 N m (88 18 lb in).
Install the fuel lines and fittings as needed.Torque to specifications.
Lubricate the O-Ring seals and the sleeve boreof the injector sparingly with clean engine oil.
Install injector in the cylinder head. Positionthe injector into the cylinder head. Use your hand to install the injectorinto the cylinder head. Install socket head bolt on the exhaust side ofthe hold down bracket. Tighten the exhaust side of socket head bolt untilthe bolt is seated. Install and tighten the inlet side of socket head boltto a torque of 12 1 N m (9 1 lb ft).
Install the valve mechanism cover. Refer to Disassemblyand Assembly, "Valve Mechanism Cover - Remove and Install".
If the o-rings are damaged and needreplaced.
Use Tool (A) and Tool (B) to install the upper high-pressure seal pack.
Install the upper seal pack first. Then installthe middle seal pack. Finally, install the bottom O-Ring Seal.
Install Tool (A) on the injector.
Use Tool (B) to install backup rings and O-ringseal on the unit injector. Lubricate the O-ring seals and