Information injection-pump assembly
ZEXEL
101495-3220
1014953220
Rating:
Cross reference number
ZEXEL
101495-3220
1014953220
Zexel num
Bosch num
Firm num
Name
101495-3220
INJECTION-PUMP ASSEMBLY
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
Overflow valve
131424-7420
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
3.2
3.15
3.25
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
1000
1000
1000
Average injection quantity
mm3/st.
70.2
69.2
71.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.8+-0.5
Pump speed
r/min
450
450
450
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.
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 LIMIT: RAL
(3)Rack difference between N = N1 and N = N2
----------
K=12 RAL=12.5+0.2mm N1=1000r/min N2=750r/min
----------
----------
K=12 RAL=12.5+0.2mm N1=1000r/min N2=750r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=8deg+-5deg b=29deg+-5deg c=32deg+-3deg
----------
----------
a=8deg+-5deg b=29deg+-5deg c=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=1deg+-5deg b=53deg+-5deg
----------
----------
a=1deg+-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=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Introduction
The problem that is identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is listed below.Problem
A significant amount of HEUI pumps and injectors have been returned, but no cause of failure can be determined.Solution
Diagnostic procedures have been updated and have been incorporated into the following publications:
Special Instruction, REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)"
Troubleshooting, "Injection Actuation Pressure - Test"Note: These publications have been translated into Mandarin and Spanish.In addition, a new troubleshooting checklist is included with all service repair for HUEI pumps and HEUI injectors. The checklist is a summary of the diagnostic procedure steps to be confirmed before a suspect component is replaced. The checklist must be completed and returned with the suspect components in order to aid engineering to determine the cause of failure.Following the instructions step-by-step is critical in order to diagnose the failed component correctly. Do not skip steps in the procedures. Skipping steps in the procedure will lead to incorrect diagnosis of the problem.
The problem that is identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is listed below.Problem
A significant amount of HEUI pumps and injectors have been returned, but no cause of failure can be determined.Solution
Diagnostic procedures have been updated and have been incorporated into the following publications:
Special Instruction, REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)"
Troubleshooting, "Injection Actuation Pressure - Test"Note: These publications have been translated into Mandarin and Spanish.In addition, a new troubleshooting checklist is included with all service repair for HUEI pumps and HEUI injectors. The checklist is a summary of the diagnostic procedure steps to be confirmed before a suspect component is replaced. The checklist must be completed and returned with the suspect components in order to aid engineering to determine the cause of failure.Following the instructions step-by-step is critical in order to diagnose the failed component correctly. Do not skip steps in the procedures. Skipping steps in the procedure will lead to incorrect diagnosis of the problem.
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Komatsu
101495-3220
INJECTION-PUMP ASSEMBLY