101472-3600 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014723600 6144711150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101472-3600 1014723600

KOMATSU 6144711150 6144711150

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Service parts 101472-3600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101047-8190

3. GOVERNOR 105400-1590

4. SUPPLY PUMP 105220-1860

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:

101472-3600 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-1020 as _

Cross reference number

ZEXEL 101472-3600 1014723600

KOMATSU 6144711150 6144711150

Zexel num

Bosch num

Firm num

Name

101472-3600

6144711150 KOMATSU

INJECTION-PUMP ASSEMBLY
4D94 * K

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

Rack position
Point A R=A

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 1225 1225 1225

Average injection quantity mm3/st. 29 28 30

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.8

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 9 8.2 9.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1
----------
K=10 R1=18+-1mm
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=32deg+-3deg c=23deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

----------
a=50deg24min+-3deg b=9deg36min+-30min

Information:

Illustration 2 g06542023
(T1a) Eccentric gasket
Install adjustment tool (T1) on the injector for center cylinder (2) using eccentric gasket (T1a). Install eccentric gasket (T1a) over the check valve in place of the O-ring.
Illustration 3 g06542029
(T1b) Supply fitting
(T1c) Purge hose
(T2) Inlet hose
Connect a suitable container filled with clean diesel fuel to supply fitting (T1b) using inlet hose (T2). Place a small cup under purge hose (T1c).
Illustration 4 g06536094
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Rotate the engine in the direction of rotation (clockwise) until center cylinder (2) is at Top-Dead-Center (TDC) with the compression stroke. The reference mark for center cylinder (2) must be aligned with the TDC index mark (A) and the valves must be closed.
Illustration 5 g06536129
Center cylinder (2) at 11° Before-Top-Dead-Center (BTDC)
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Illustration 6 g06542031
(T1c) Purge hose
Raise the fuel container above the level of the injector. Rotate the engine counterclockwise until reference mark (2) is to the left of the 11° Before-Top-Dead-Center (BTDC) mark or until fuel is observed flowing from purge hose (T1c).
Illustration 7 g06542019
(T1c) Purge hose
Rotate the engine clockwise and stop immediately when the fuel stops flowing from purge hose (T1c). The beginning of injection has been reached when the fuel stops flowing.
Illustration 8 g06536129
Center cylinder (2) rotated 11°
(1) Drive clutch side cylinder
(2) Center cylinder
(3) Alternator side cylinder
(A) TDC index mark
Observe the alignment of the reference mark for center cylinder (2) and the 11° BTDC mark.Note: If mark (2) aligns with the 11° mark, timing is correct and proceed to Step 9. If marks are not aligned, the injector timing must be adjusted. Adjust injector timing using the procedure in Step 8.
Observe the position of the reference mark for center cylinder (2) and the mark at 11° of rotation for BTDC. Note if the injector timing is early or late.Note: If the reference mark for center cylinder (2) is left of the 11° BTDC mark, injector timing is early. If the mark is to the right, injector timing is late.
Illustration 9 g06536148
(B) Jam nut
Rotate the engine to align the reference mark for center cylinder (2) and the 11° BTDC mark. Loosen jam nut (B) on the fuel injector timing adjustment screw. For late timing, proceed to Step 8b. For early timing, proceed to Step 8c
Illustration 10 g06536146
(C) Adjustment screw
Late Timing: While watching purge hose (T1c), turn adjustment screw (C) clockwise until fuel flow stops.
Early Timing: While watching purge hose (T1c), turn adjustment screw (C) counterclockwise until fuel flow starts. Then, turn adjustment screw (C) clockwise until fuel flow stops.
Hold adjustment screw (C) and tighten jam nut (B) securely. Check the injector timing by repeating Steps 5 through 7.
Remove adjustment tool (T1) and install with eccentric gasket (T1a) on the injector for drive clutch side cylinder (1). Rotate the engine 120° clockwise using the reference mark for cylinder (1). Repeat Steps 4 through 8.
Repeat Step 9 for alternator side cylinder (3).
Illustration 11 g06543249
(1) 562-0435 O-Ring Seal
Remove adjustment tool (T1) and eccentric gasket (T1a). Reinstall the fuel rail with four new