101601-3090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016013090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-3090 1016013090

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Cross reference number

ZEXEL 101601-3090 1016013090

Zexel num

Bosch num

Firm num

Name

101601-3090
101601-3091

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

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 10.6

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 77.5 76.5 78.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.8

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 78.5 76.5 80.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.3+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.9 7.7 10.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

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)Rack difference between N = N1 and N = N2
----------
K=12 N1=1200r/min N2=600r/min
----------

Speed control lever angle

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

----------
a=23deg+-5deg b=15deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(0deg)

Information:

1. Remove the seat retaining ring (1) and pin (2). 2. Remove the seat (3), bolt (4), washers (5) and spring (6).3. Remove the sleeve and bearing assembly from the cylinder and weight assemblies. 4. Remove the retaining ring (7) from sleeve (8).5. Remove bearing (9) and races (10) from sleeve (8). 6. Remove the valve (11) from piston (12).7. Remove the cylinder-to-weight assembly retaining ring (13).8. Remove the weight assembly (14).9. Remove piston (12) and sleeve (15) from the cylinder (16).10. Remove the O-ring seal from the sleeve (15). 11. Remove the speed limiter plug (17), spring (18), and plunger (19) from the governor housing.12. Remove the high idle screw (21) and low idle screw (20). 13. Remove the lever assembly-to-shaft assembly retaining bolt (23) and lock.14. Remove the shaft assembly (22) and lever assembly (24) from governor housing.15. Remove the seal from governor housing. 16. Remove two retaining bolts (25) and lock. Remove the lever (26) and shaft (27) from idle screw housing.17. Remove two seals and bearing from idle screw housing.Assemble Governor
1. Using tool (A) install the inner seal in idle screw housing with spring side of seal facing the driver. Install bearing and outer seal with lip of the seal toward the inside of the housing. Lubricate lip of seal with clean SAE 30 engine oil.2. Position the shaft and lever in the idle screw housing. Install the retaining bolts and lock. 3. Using tool (A), install the seal in the governor housing with spring side of seal toward inside of governor housing. Lubricate lip of seal with clean SAE 30 engine oil.4. Position the lever assembly and shaft in the governor housing. Install the retaining bolt and lock.5. Install the high and low idle screws in the governor housing.6. Install the speed limiter plug, spring, and plunger in the governor housing. 7. Install the O-ring seal (3) on sleeve (4).8. Install piston (2) and sleeve (4) in the cylinder (1). 9. Position the weight assembly (6) on cylinder (7), and install retaining ring (5). 10. Install the valve (9) in piston (10).11. Install the bearing and races in sleeve. Install retaining ring. Install the sleeve and bearing assembly (8) on valve (9). 12. Position the seat (12), bolt (11), washers and spring on the valve (9). Install the retaining pin (14) and retaining ring (13).concluding step: a) connect governor to fuel injection pump housing