101495-3140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953140 6202731142

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101495-3140 1014953140

KOMATSU 6202731142 6202731142

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Service parts 101495-3140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

101049-8760

3. GOVERNOR 105400-6001

4. SUPPLY PUMP 105220-5610

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4850

11. Nozzle and Holder 6202-13-3500

12. Open Pre:MPa(Kqf/cm2) 22.1{225}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE 105017-0840

15. NOZZLE SET

Include in #1:

101495-3021 as _

101495-3140 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101495-3140 1014953140

KOMATSU 6202731142 6202731142

Zexel num

Bosch num

Firm num

Name

101495-3140

6202731142 KOMATSU

INJECTION-PUMP ASSEMBLY
4D95S * 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 9

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 36.4 35.4 37.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 350 350 350

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)Notch fixed: K (2)RACK LIMIT: RAL
----------
K=20 RAL=12+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(17deg)+-5deg b=(24deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
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)-
----------

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

Information:

Introduction
This Special Instruction contains the necessary procedure in order to install unit injectors for 3114, 3116, and 3126 MUI engines.Removal and Installation Procedure
Note: To avoid damage to the unit injector during removal of the unit injector from the cylinder head, refer to the Service Manual for the removal procedure of the unit injector.Use the latest process for servicing the unit injector sleeves in the cylinder head before you install replacement unit injectors. Refer to the Service Manual and other service news articles in order to find the latest service information, including new tools and procedures.Before a new unit injector or a remanufactured unit injector is installed into an engine, take adequate precautions in order to clean the internal fuel lines and the unit injector sleeve. Also, install a new Caterpillar high efficiency fuel filter.Lubricate the injector rack bar with clean diesel fuel or 1U-8265 Penetrating Oil .
Illustration 1 g02144296
Incorrect testing procedure for the tappet springDo not depress the tappet spring. Refer to Illustration 1. Do not force the injector rack bar in and out since this action may damage the internal parts of the unit injector. A tight rack on a unit injector that is not installed in the engine is not an indication of a faulty unit injector. Forcing the injector rack bar in and out may cause the unit injector to become damaged. Forcing the injector rack bar in and out may possibly void all the warranty.Do not test the unit injectors prior to engine installation. The unit injectors are tested 100% at the factory and Pop Testing may contaminate the unit injector.Before you install the unit injector, apply clean engine oil on the O-ring seals for ease of installation.Install the unit injector according to the procedure in the Service Manual by using 173-1530 Injector Seating Tool . Tighten the unit injector clamp retaining bolt to a torque of 12 3 N m (9 2 lb ft).Verify the following parameters and settings according to the procedures in the Service Manual: unit injector synchronization, fuel setting, fuel timing and valve lash. Adjust the parameters and settings in order to meet specifications only.