101492-3910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014923910 6205711410

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101492-3910 1014923910

KOMATSU 6205711410 6205711410

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Cross reference number

ZEXEL 101492-3910 1014923910

KOMATSU 6205711410 6205711410

Zexel num

Bosch num

Firm num

Name

101492-3910

6205711410 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95L * 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 3.6 3.55 3.65

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 10.8

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 56.2 55.2 57.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9+-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.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1 (3)Idle sub spring setting: L1. (4)Rack difference between N = N1 and N = N2 (5)Rack difference between N = N3 and N = N4
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K=10 R1=(17.5)mm L1=6.6-0.5mm N1=900r/min N2=400r/min N3=900r/min N4=250r/min
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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
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aa=900r/min bb=750r/min
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a=(2deg)+-5deg b=(25deg)+-5deg c=(7deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=43.5deg+-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)-
----------

----------
a=59deg36min+-3deg b=0deg24min+-30min

Information:

AFFECTED PRODUCT
Model Identification Number
797 5YW00260
797B JSM00151-00152, 220-225, 236-237, 244, 256
797F LAJ00142-00144, 189, 200-202, 227-228, 251-255, 262, 264, 266-269, 276, 283, 285, 287, 292-293, 295-296, 308, 311-314, 316-322, 327-328, 341, 343-344, 350-351, 365, 372-373, 445-446, 458-461, 464-466, 468, 476-477, 483, 491-494, 507-512, 523-525, 554-561, 569-571, 573-584, 596, 634-636, 639, 642-643
PARTS NEEDED
Qty
Part Number Description
4 8T2223 BOLT-SOCKET HD
1 8T9524 SEAL-O-RING
1 20R5566 INJECTOR GP-F -G
1 2287108 SEAL-O-RING-STOR
1 2300940 SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Perform a Fuel Status Verification Test (FSVT).
Replace injectors showing INJ-2, INJ-7 or INJ-12 code.
Refer to KENR6052 for removal and installation instructions.
To qualify for this support program;
-Machine must be operating with the Clean Fuel Module (CFM)
-Machine must be operating most current software release in SIS Web.
-Attach a Product Status Report to the claim form
-Provide the ECM Replacement files with the claim
-Conduct a review of the maintenance history of the machine to ensure no High Pressure Fuel Pump failure within two weeks of injector failure
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-12 mo 100.0% 0.0% 0.0% 100.0% 0.0% 0.0%
6001-9000 hrs,
13-24 mo 33.0% 0.0% 0.0% 50.0% 50.0% 50.0%
This is a 2.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
This program can be claimed multiple times per machine.
PARTS DISPOSITION
Hold the fuel injector for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.