Information injection-pump assembly
ZEXEL
101492-3820
1014923820
KOMATSU
6204711441
6204711441
Rating:
Service parts 101492-3820 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3102
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-3820
1014923820
KOMATSU
6204711441
6204711441
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
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
9.6
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
36.5
35.5
37.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
6.2
5.2
7.2
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)The torque control spring must does not have a set force.
(4)Idle sub spring setting: L1.
(5)Rack difference between N = N1 and N = N2
----------
K=12++ R1=(17.5)mm L1=7.5-0.5mm N1=850r/min N2=400r/min
----------
----------
K=12++ R1=(17.5)mm L1=7.5-0.5mm N1=850r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Stopper bolt setting
(3)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=(6deg)+-5deg
----------
aa=900r/min bb=750r/min
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=(6deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=4deg+-5deg b=53deg+-5deg
----------
----------
a=4deg+-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)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
For After failure, and additional 9.0 hours are allowed. A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement. Check that the fuel pump has not suffered a mechanical failure that has resulted in a head gasket failure, such as mechanical failure of the advance box due to air ingress. Head gasket failure due to mechanical failure of the fuel pump is not covered by this service letter.
If the head gasket has not failed follow the rework procedure for fuel injection pump replacement only.
Head gasket replacement:
Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1.
Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained.
Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect".
Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information.
Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines.
Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information.
Fuel injection pump replacement:
Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC".
Install the new 483-2328 Fuel Pump as per Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210". Record the installed fuel pump serial number in claim story. It is essential to install the fuel injection pump with the correct engine position to achieve the correct fuel injection timing and the