Information injection-pump assembly
ZEXEL
101492-3641
1014923641
KOMATSU
6205711230
6205711230
Rating:
Service parts 101492-3641 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
101492-3641
1014923641
KOMATSU
6205711230
6205711230
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-2-4-3
Pre-stroke
mm
3.2
3.15
3.25
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
9.9
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
69.5
68.5
70.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.6+-0.5
Pump speed
r/min
475
475
475
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
----------
K=11 R1=(17.5)mm N1=1050r/min N2=750r/min N3=1050r/min N4=300r/min
----------
----------
K=11 R1=(17.5)mm N1=1050r/min N2=750r/min N3=1050r/min N4=300r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=14deg+-5deg b=32deg+-3deg c=30deg+-5deg
----------
----------
a=14deg+-5deg b=32deg+-3deg c=30deg+-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=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Start By:a. remove all turbochargersb. remove crankshaft rear seal and wear sleeve 1. Disconnect connector (1). 2. Attach Tool (A) and fasten a hoist.3. Remove four bolts (3) and stack (2). The weight of the stack and hardware is 45 kg (100 lb). 4. Remove hose clamp (6).5. Remove five bolts (5) and support (4).6. Repeat Steps 4 and 5 for the other side of the engine. 7. Remove six bolts (7) that connect oil pan (8) to flywheel housing (9). Loosen the rest of the bolts that hold the oil pan in position. 8. Attach Tool (A) to the flywheel housing and a hoist. 9. Lift the end of the engine enough so a 1/2 in. Hardened Washer (10) can be installed on each side of the engine between the oil pan and the cylinder block.10. Install blocks under the oil pan to support the engine when the flywheel housing is removed. Lower the engine onto the blocks. 11. Remove twenty one bolts (11) and flywheel housing (9). The weight of the flywheel housing is 91 kg (200 lb).Install Flywheel Housing
1. Install two 1/2 -13 NC × 4 in. Long Guide Bolts in the cylinder block. Make sure gasket (12) is in position. The cylinder block, both sides of gasket (12) and the surface of the flywheel housing that makes contact with the gasket must not have any oil, fuel, water or gasket adhesive on them when the flywheel housing is installed on the engine.2. Install Tool (A) on the flywheel housing. Install flywheel housing (9) on the engine. The weight of the flywheel housing is approximately 91 kg (200 lb). Leave Tool (A) attached.
Torque Sequence Put 9S-3263 Thread Lock on bolts (17) through (20) before installation.3. Install the bolts that hold the flywheel housing in place.4. Use the following procedure to tighten the bolts: a. Tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb ft).b. Tighten bolts 9 through 20 in number sequence to 55 7 N m (41 5 lb ft).c. Again, tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb ft).d. Again, tighten bolts 9 through 20 in number sequence to 55 7 N m (41 5 lb ft). If a new gasket is installed, cut the ends of the gasket so it is even with the bottom of the cylinder block.5. Use Tool (A) and a hoist to lift the flywheel housing and engine enough so that the washers between the oil pan and the cylinder block can be removed. 6. Tighten the bolts that hold the oil pan to the cylinder block. Install six bolts (7) that hold oil pan (8) to flywheel housing (9). 7. Install support (4) with five bolts (5). Install clamp (6) to a torque of 7.0 1.5 N m (5 1 lb ft).8. Repeat Step (7) for the other side of the engine.
1. Install two 1/2 -13 NC × 4 in. Long Guide Bolts in the cylinder block. Make sure gasket (12) is in position. The cylinder block, both sides of gasket (12) and the surface of the flywheel housing that makes contact with the gasket must not have any oil, fuel, water or gasket adhesive on them when the flywheel housing is installed on the engine.2. Install Tool (A) on the flywheel housing. Install flywheel housing (9) on the engine. The weight of the flywheel housing is approximately 91 kg (200 lb). Leave Tool (A) attached.
Torque Sequence Put 9S-3263 Thread Lock on bolts (17) through (20) before installation.3. Install the bolts that hold the flywheel housing in place.4. Use the following procedure to tighten the bolts: a. Tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb ft).b. Tighten bolts 9 through 20 in number sequence to 55 7 N m (41 5 lb ft).c. Again, tighten bolts 1 through 8 in number sequence to 136 14 N m (100 10 lb ft).d. Again, tighten bolts 9 through 20 in number sequence to 55 7 N m (41 5 lb ft). If a new gasket is installed, cut the ends of the gasket so it is even with the bottom of the cylinder block.5. Use Tool (A) and a hoist to lift the flywheel housing and engine enough so that the washers between the oil pan and the cylinder block can be removed. 6. Tighten the bolts that hold the oil pan to the cylinder block. Install six bolts (7) that hold oil pan (8) to flywheel housing (9). 7. Install support (4) with five bolts (5). Install clamp (6) to a torque of 7.0 1.5 N m (5 1 lb ft).8. Repeat Step (7) for the other side of the engine.