101601-3030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016013030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-3030 1016013030

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Service parts 101601-3030 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:

101601-3030 as INJECTION-PUMP ASSEMBLY

101691-3040 as _

Cross reference number

ZEXEL 101601-3030 1016013030

Zexel num

Bosch num

Firm num

Name

101601-3030
101601-3031

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 10.8

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 101.5 100.5 102.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.4+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 10.1 8.9 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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 20 33.4

Boost pressure mmHg 200 150 250

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
----------
K=7
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

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

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
----------

Information:

FEED ENGAGED
21. Slot. 22. Pin. 23. Knob. To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).
LATER FEED MECHANISM
A. Lever.Place adapter (24) into boring bar and tighten setscrew (25).
ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 .0005 in. (94.425 0.013 mm).
BORING BEARING BORE
26. 1P2363 Universal. If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.
DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.The bluing applied to the bearing bore indicates the condition of the bore at the correct bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).
CHECKING BORE (Typical Example)Line Boring Main Bearing Bores
Line bore all main bearing bores if bearing caps or saddles are distorted.Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore. There must be two good bores for locating centering rings.
CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.
CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.
BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N m) and a maximum of 50 lb. ft. (70 N m) while spinning boring bar (5) to check for binding. Centering rings (1) must be seated in bearing saddles after tightening.Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.
INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly