Information injection-pump assembly
ZEXEL
101495-3010
1014953010
KOMATSU
6204711650
6204711650
Rating:
Service parts 101495-3010 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6206-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101495-3010
1014953010
KOMATSU
6204711650
6204711650
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
10
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
40.7
39.7
41.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.3+-0.5
Pump speed
r/min
240
240
240
Average injection quantity
mm3/st.
7
6
8
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 difference between N = N1 and N = N2
----------
K=17 N1=1500r/min N2=900r/min
----------
----------
K=17 N1=1500r/min N2=900r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=43deg+-5deg b=27deg+-5deg
----------
----------
a=43deg+-5deg b=27deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
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)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Parts Location
Illustration 2 g01601433
(1) 308-4943 Diesel Particulate Filter Group (2) 235-3963 Clamp Assembly (3) 308-4945 Bracket Assembly (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer (6) 241-9265 Muffler Clamp Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606937
Typical Example (11) Existing muffler assembly (12) Existing bracket assembly (13) Support Assembly (14) Muffler Clamp (15) Tube assembly (16) Engine lifting plate (17) Bolt (18) Hard washer (19) Bolt
Remove existing muffler assembly (11) and bracket assembly (12). Set aside the three 8T-4183 Bolts (17), the five 8T-4184 Bolts (19) and the eight 5P-1076 Hard Washers (18). These parts will be reused in Steps 2 and 3. Refer to Illustration 3.
Illustration 4 g01601354
(3) 308-4945 Bracket Assembly (17) Bolt (18) Hard washer
Install 308-4945 Bracket Assembly (3) onto support assembly (13) by reusing three bolts (17) and three hard washers (18) that were removed in Step 1. Refer to Illustrations 3 and 4.
Illustration 5 g01601373
(19) Bolt
Reuse five bolts (19) and five hard washers (18) removed in Step 1 to secure bracket assembly (3) to engine lifting plate (16). Refer to Illustrations 3 and 5.
Illustration 6 g01601413
(2) 235-3963 Clamp Assembly (Lower half) (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer
Remove the two bolts, two hard washers, two lock washers, and two nuts from each 235-3963 Clamp Assembly (2). Keep these parts together with the upper half of clamp assembly (2). These parts will be reinstalled in Step 8.
Install the lower half of 235-3963 Clamp Assembly (2) by using two 8T-4183 Bolts (4) and two 5P-8245 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Repeat for the other clamp assembly (2). Refer to Illustration 6.
Illustration 7 g01601473
(1) 308-4943 Diesel Particulate Filter Gp
Install 308-4943 Diesel Particulate Filter Group (1) onto the lower halves of clamp assemblies (2). The weight of the diesel particulate filter group is approximately 40 kg (88 lb). Make sure that the inlet tube (not shown) of the inlet module of the diesel particulate filter fits into tube assembly (15). Use a new 241-9265 Muffler Clamp (6) to secure the connection. Refer to Illustrations 3 and 7.
Illustration 8 g01601333
(2) 235-3963 Clamp Assembly (Upper half) (2a) Bolt (2b) Hard washer (2c) Lock washer (2d) Nut
Once you have properly installed the tube assembly, tighten both bolts (4) to secure the bottom half of clamp assembly (2). Repeat for the other clamp assembly (4). Install the upper half of clamp assembly (2) by using two bolts (2a) and two hard washers (2b) through the upper clamp assembly, and two lock washers (2c) and two nuts (2d) on the lower clamp assembly. Repeat for the other clamp assembly. Refer to Illustration 8.
Reconnect the drain lines.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications" for information regarding the installation and the operation of the exhaust monitor.The exhaust
Illustration 2 g01601433
(1) 308-4943 Diesel Particulate Filter Group (2) 235-3963 Clamp Assembly (3) 308-4945 Bracket Assembly (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer (6) 241-9265 Muffler Clamp Installation Procedure
Diesel Particulate Filter Installation
Illustration 3 g01606937
Typical Example (11) Existing muffler assembly (12) Existing bracket assembly (13) Support Assembly (14) Muffler Clamp (15) Tube assembly (16) Engine lifting plate (17) Bolt (18) Hard washer (19) Bolt
Remove existing muffler assembly (11) and bracket assembly (12). Set aside the three 8T-4183 Bolts (17), the five 8T-4184 Bolts (19) and the eight 5P-1076 Hard Washers (18). These parts will be reused in Steps 2 and 3. Refer to Illustration 3.
Illustration 4 g01601354
(3) 308-4945 Bracket Assembly (17) Bolt (18) Hard washer
Install 308-4945 Bracket Assembly (3) onto support assembly (13) by reusing three bolts (17) and three hard washers (18) that were removed in Step 1. Refer to Illustrations 3 and 4.
Illustration 5 g01601373
(19) Bolt
Reuse five bolts (19) and five hard washers (18) removed in Step 1 to secure bracket assembly (3) to engine lifting plate (16). Refer to Illustrations 3 and 5.
Illustration 6 g01601413
(2) 235-3963 Clamp Assembly (Lower half) (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer
Remove the two bolts, two hard washers, two lock washers, and two nuts from each 235-3963 Clamp Assembly (2). Keep these parts together with the upper half of clamp assembly (2). These parts will be reinstalled in Step 8.
Install the lower half of 235-3963 Clamp Assembly (2) by using two 8T-4183 Bolts (4) and two 5P-8245 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Repeat for the other clamp assembly (2). Refer to Illustration 6.
Illustration 7 g01601473
(1) 308-4943 Diesel Particulate Filter Gp
Install 308-4943 Diesel Particulate Filter Group (1) onto the lower halves of clamp assemblies (2). The weight of the diesel particulate filter group is approximately 40 kg (88 lb). Make sure that the inlet tube (not shown) of the inlet module of the diesel particulate filter fits into tube assembly (15). Use a new 241-9265 Muffler Clamp (6) to secure the connection. Refer to Illustrations 3 and 7.
Illustration 8 g01601333
(2) 235-3963 Clamp Assembly (Upper half) (2a) Bolt (2b) Hard washer (2c) Lock washer (2d) Nut
Once you have properly installed the tube assembly, tighten both bolts (4) to secure the bottom half of clamp assembly (2). Repeat for the other clamp assembly (4). Install the upper half of clamp assembly (2) by using two bolts (2a) and two hard washers (2b) through the upper clamp assembly, and two lock washers (2c) and two nuts (2d) on the lower clamp assembly. Repeat for the other clamp assembly. Refer to Illustration 8.
Reconnect the drain lines.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications" for information regarding the installation and the operation of the exhaust monitor.The exhaust