101492-3680 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014923680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101492-3680 1014923680

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Cross reference number

ZEXEL 101492-3680 1014923680

Zexel num

Bosch num

Firm num

Name

101492-3680

KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95L *

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 3.2 3.15 3.25

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 7.7

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 54.1 53.1 55.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.9+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
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
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K=9
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=(43deg)+-5deg b=(26deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=26.5deg+-5deg b=53deg+-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)-
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a=58deg+-3deg b=2deg+-30min

Information:

start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove the bolts (1) that hold the governor housing (2) to the fuel injection pump housing.3. Remove the governor housing (2). 4. Remove two springs (4) and the seat (5) from the governor housing.5. Remove the seat (7) from the shaft.6. Remove the spring (6) from the shaft.7. Remove the cover (3) from the pump housing. 8. Remove the shaft (8) and the lever (9) from the pump housing. 9. Remove the thrust collar (11) from the shaft.10. Remove the cover (10) from the pump housing. 11. Loosen the two bolts (13) that hold the torque spring assembly (12) and remove it from the pump housing. 12. Remove the pin (15) from the pump housing.13. Remove the screw (14) and the nut (16) from the pump housing.14. Remove the ring that holds the lever and remove the lever (18) from the dowel (17).15. Remove the dowel (17) from the pump housing. Dowel does not need to be removed unless camshaft is to be removed.
Pull on the shield only a small amount in each location so it will not have distortion or damage. A damaged shield must be replaced.
16. Remove the shield (19) from the camshaft with tool (B). 17. Install the timing pin (C) to hold the camshaft.18. Remove the bolts (20) that hold the flyweight assembly to the camshaft. 19. Remove the flyweight assembly (21) from the camshaft.20. Remove the timing pin (C) from the pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on the bracket assembly (A).2. Install the timing pin (B) to hold the camshaft.3. Put the flyweight assembly (1) in position on the camshaft. Be sure the pin that holds the shaft (2) is in position on the back of the flyweight assembly.4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 10 2 lb. ft. (1.38 0.28 mkg).5. Remove the timing pin (B). 6. Put the shield (3) in position over the flyweights. 7. Use the driver (C) to install the shield the remainder of the way on to the camshaft. 8. Put a new O-ring seal on the dowel (4) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing. 9. Put the lever (8) on the dowel (4) and install the ring that holds it on the dowel.10. Install the screw (6) and the nut (7) in the pump housing.11. Install the pin (5) in the pump housing. 12. Put the torque spring assembly (10) in position on the housing and tighten the two bolts (11) that hold it to the housing.13. Install the cover (9) on the pump housing. 14. Put the thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire