101472-3540 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014723540 6144751301

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101472-3540 1014723540

KOMATSU 6144751301 6144751301

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Service parts 101472-3540 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101047-8180

3. GOVERNOR 105400-1340

4. SUPPLY PUMP 105220-4700

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1530

11. Nozzle and Holder 6142-12-3300

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105081-2190

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101421-4980 as _

101472-3540 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101472-3540 1014723540

KOMATSU 6144751301 6144751301

Zexel num

Bosch num

Firm num

Name

101472-3540

6144751301 KOMATSU

INJECTION-PUMP ASSEMBLY
4D94 *

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-4-3

Pre-stroke mm 2.2 2.15 2.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 8.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 35.1 34.1 36.1

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 9

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 42.8 41.8 43.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.3

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9 8.2 9.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_04

Adjusting point D

Rack position 9

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 31.9 31.9 34.9

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1 (3)The torque control spring does not operate.
----------
K=19 R1=18+-1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=25.5deg+-5deg b=32deg+-3deg c=24.5deg+-5deg

Information:

Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Reference Section
Refer to Service Magazine, M0082326, "Diesel Exhaust Fluid (DEF) Contamination on C4.4 Machine Engines".Refer to Service Magazine, M0096547, "Diesel Exhaust Fluid (DEF) Pump Filter Maintenance on Certain C4.4 Machine Engines".Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".Problem
There have been instances of returned DEF pumps that have no fault found or indicating contamination.Resolution
Complete the form below and attach to any SIMSi claim in addition to a Product Status Report (PSR) from before any troubleshooting was performed or any diagnostic codes were cleared.
Use the electronic service tool to download a PSR with Histograms.
Enter the diagnostic codes that require troubleshooting: ___
Perform the correct troubleshooting procedure for any active diagnostic codes. Refer to Troubleshooting, Diagnostic Trouble Codes.
If the troubleshooting procedure requests that the DEF is tested for contamination or concentration , record the results in Table 1 and Table 2.
For other DEF-related troubleshooting procedures, follow the applicable troubleshooting steps and record the results in Table 3.
Table 1
DEF Contamination
Step Instruction Completed Result Units
1 Perform the test procedure for DEF contamination. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test.
2 Compensator measurements. Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".
Diameter (A) mm
Length (B) mm
3 If contamination is present, confirm that DEF system has been flushed. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush
Table 2
DEF Concentration
Step Instruction Completed Result Units
1 Perform the test procedure for DEF concentration. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test. %
2 If the DEF concentration is out of specification, confirm that the DEF tank has been drained and filled with the correct specification of DEF. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid - Fill.
Table 3
DEF Troubleshooting
Step Instruction Completed Result Units
1 Latest engine and Dosing Control Unit (DCU) software has been installed. Refer to Troubleshooting, ECM Software - Install.
2 DEF lines have been checked for restrictions.
3 DEF pump has been checked for restrictions.
4 DEF injector has been checked for restrictions.
5 DEF lines have been inspected for leaks.
6 Confirm the DEF pressure. Refer to Troubleshooting, DEF Pressure Does Not Respond. kPa
7 DEF dosing system accuracy test has been performed. Refer to Troubleshooting, Aftertreatment SCR System Dosing - Test.
8 DEF pump filter replaced.
9 "Aftertreatment System Functional Test" performed. Refer to Troubleshooting, Service Tool Features.