101601-3000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016013000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-3000 1016013000

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Service parts 101601-3000 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

3. GOVERNOR 105411-0680

4. SUPPLY PUMP 105210-4450

5. AUTOM. ADVANCE MECHANIS 105614-3070

6. COUPLING PLATE 105662-0650

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4950

11. Nozzle and Holder 6138-11-3101

12. Open Pre:MPa(Kqf/cm2) 24.5{250}

13. NOZZLE-HOLDER 105031-4360

14. NOZZLE 105015-4570

15. NOZZLE SET

Include in #1:

101495-3530 as _

101601-3000 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-3000 1016013000

Zexel num

Bosch num

Firm num

Name

101601-3000
101601-3001

KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D110 *

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 1-5-3-6- 2-4

Pre-stroke mm 4 3.95 4.05

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.7

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 93.8 92.8 94.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_02

Adjusting point B

Rack position 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 97 95 99

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_03

Adjusting point C

Rack position 6.8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.2 9 11.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position 9.4

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position 11

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.8

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1250

Advance angle deg. 4 3.5 4.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator stroke: BCL
----------
K=12 BCL=1.6+-0.1mm
----------

Speed control lever angle

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

----------
a=12deg+-5deg b=32deg+-3deg c=23deg+-5deg

0000001501 LEVER

(F) P/N: Part number of the shim L1:Thickness (mm) 1. Adjustment of the control lever (1)Perform idling with the control lever (A) contacting the pushrod (B). At this time, confirm that the spring (C) is not compressed by control lever (A)'s operating torque. (2)To set the stop position, compress spring (C) using the control lever (A) and adjust the rack so that it contacts the guide screw (D) at position L2. Then, set and fix using the lock nut (E). Adjust the rack position L2 at this time using the shim (F). (3)Confirm that the control lever (A) returns to the idling position when pulled in the stop direction and then released.
----------
L2=0.2~2mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)After adjusting the injection quantity, adjust at rack position aa. (4)-
----------
aa=10.7mm
----------
a=(0deg)

Information:

TIMING MARKS2. Remove the plug from the timing pin hole in fuel injection pump housing and install timing pin (1).
TIMING PIN INSTALLED
1. FT887 Timing Pin (Fabricated Tool).3. Remove the tachometer drive adapter shaft (2).
TACHOMETER DRIVE ADAPTER
2. Tachometer drive adapter shaft.4. Using puller group (3), remove the fuel injection pump camshaft drive gear as follows. Thread the 9S8528 Bolt Assembly into the fuel injection pump camshaft. Do not force the bolt assembly. It should thread easily. Install the 9S8527 Bolt by threading it into the drive gear. Then tighten the 9S8527 Bolt with a wrench until the gear "pops" loose. Remove the gear (4) and the tool setup.
9S8520 PULLER GROUP INSTALLED
3. 9S8520 Puller Group.
REMOVING GEAR
4. Gear.5. Remove retaining screw (5), washer (6), and automatic timing advance (7) from the engine camshaft.
TIMING ADVANCE
5. Retaining screw. 6. Washer. 7. Automatic timing advance.6. Install puller (8), with spacer (10) over the shaft in the camshaft and spacer (9) on spacer (10) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
8. 1P2321 Puller. 9. 8S5579 Spacer. 10. 9S9155 Spacer.Install Camshaft Gear
1. Heat the gear to a temperature of approximately 400° F (204° C) before installing on the camshaft.
Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600° F (315° C). Heating the gear with a torch or to a temperature of more than 600° F (315° C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completely seated against the shoulder of the camshaft.
TIMING MARKS
Do not drive the gear on the camshaft. Serious damage can result to camshaft or camshaft thrust pin.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (11) in washer (6) with hole (12) in camshaft and install washer (6).
INSTALLING WASHER
6. Washer. 11. Pin. 12. Hole.5. Install retaining screw (5) and tighten to 108 36 lb. in. (124.5 41.5 cm.kg). Stake screw (5) in two places.
Stake retaining screw (5) carefully. Heavy blows on washer or retaining screw can force the shaft extension too far into the camshaft and eliminate all end clearance.
STAKING SCREW (Typical Example)
5. Retaining screw.6. After retaining screw (5) is staked, the gear and weight assembly requires .003 to .027 in. (0.08 to 0.69 mm) end clearance to prevent binding against the washer, camshaft end, or camshaft gear.7. Position the drive gear on the fuel injection pump camshaft.8. Install the tachometer drive adapter shaft and tighten the shaft retaining nut to 32 2 lb. ft. (4.4 0.3 mkg).9. Remove the timing pin from the fuel injection pump housing and install the plug in the timing hole.