Information injection-pump assembly
ZEXEL
101492-3440
1014923440
KOMATSU
6204711260
6204711260
Rating:
Service parts 101492-3440 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-3440
1014923440
KOMATSU
6204711260
6204711260
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
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive 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
8.9
Pump speed
r/min
1225
1225
1225
Average injection quantity
mm3/st.
27.7
26.7
28.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9.5
11.5
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.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
(5)The No 1 and No 2 torque control springs must have no set force.
----------
K=15 R1=(17.5)mm N1=1225r/min N2=900r/min N3=1225r/min N4=400r/min
----------
----------
K=15 R1=(17.5)mm N1=1225r/min N2=900r/min N3=1225r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=20deg+-5deg b=32deg+-3deg c=34deg+-5deg
----------
----------
a=20deg+-5deg b=32deg+-3deg c=34deg+-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)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Do not put oil on the bearings until the bearing clearance has been checked.1. Install bearings (1) in the connecting rods they were removed from. Make sure the tab in each bearing is in alignment with the notch in each connecting rod.2. Install bearings (2) in the cylinder block. Make sure the tab in each bearing is in alignment with the notch in the cylinder block. 3. Install pin (3) in the end of the crankshaft. Install the pin so that it extends a maximum of 6.4 mm (.252 in) above the surface. 4. Install the dowel in the crankshaft that puts gear (4) in the correct position. Install the dowel so that it extends 4.1 0.5 mm (.161 .020 in) above the surface of the crankshaft.5. Heat gear (4) to a maximum temperature of 233° C (451° F). Gear (4) must be installed on the crankshaft with the "V" timing mark toward the outside.6. Install gear (4) on the crankshaft. Make sure the notch in the gear is in alignment with the dowel on the crankshaft. The dimension from the rear face of the gear to the front face of the crankshaft must be 45.54 0.25 mm (1.793 .010 in). 7. Fasten Tooling (A) and a hoist to the crankshaft (5) as shown. Install the crankshaft in the engine. The weight of the crankshaft is approximately 131 kg (290 lb). 8. Make sure that "V" mark (6) on the crankshaft is in alignment with "V" mark (7) on the idler gear. The side of each thrust plate (8) with the words "BLOCK SIDE" must be installed with this side toward the cylinder block.9. Put clean oil on thrust plates (8). Install thrust plates (8) next to the center main bearings. Do not put oil on bearings (9) until the bearing clearances have been checked.10. Put bearings (9) in their original position in crankshaft main bearing caps (10).11. Check the crankshaft main bearing clearance with Plastigage as follows:a. Put a piece of Plastigage between the crankshaft bearing journal surface and bearing (9).b. Install the crankshaft main bearing caps (10) with the arrow on each cap toward the front of cylinder block. Each crankshaft main bearing cap has a number on the bottom surface and must be installed in the same position as the correct number on the left side of the cylinder block.c. Put 2P-2506 Thread Lubricant on the threads of the cap bolts. Install the cap bolts finger tight.d. Tighten the bolts on the tab end of the caps first to a torque of 258 14 N m (190 10 lb ft).e. Tighten the bolts on the other end of the caps to a torque of 258 14 N m (190 10 lb ft).
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
f. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end of the cap
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
f. Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end of the cap