Information injection-pump assembly
ZEXEL
101605-3230
1016053230
KOMATSU
6138721871
6138721871
Rating:
Service parts 101605-3230 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
22.1(225)
15.
NOZZLE SET
Include in #1:
101605-3230
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-5373
as _
Cross reference number
ZEXEL
101605-3230
1016053230
KOMATSU
6138721871
6138721871
Zexel num
Bosch num
Firm num
Name
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-5-3-6-
2-4
Pre-stroke
mm
4
3.95
4.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
91.6
90.6
92.6
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
750
750
750
Average injection quantity
mm3/st.
125.4
123.4
127.4
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.3
Pump speed
r/min
775
775
775
Average injection quantity
mm3/st.
20
18.8
21.2
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
8.7+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
13.5
12.3
14.7
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Idle sub spring setting: L1.
(3)Rack difference between N = N1 and N = N2
----------
K=7 L1=7.4-0.5mm N1=750r/min N2=400r/min
----------
----------
K=7 L1=7.4-0.5mm N1=750r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Stopper bolt setting
(3)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=22deg+-5deg b=6deg+-5deg c=1deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=22deg+-5deg b=6deg+-5deg c=1deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At shipping
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Information:
Start By:a. remove spacer plate
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Put compression on valve spring (2) with tool (A), and remove locks (1).2. Remove tool (A), rotocoil, spring, valve stem oil shield and valve. Put identification marks on valves with respect to their location in the cylinder head. 3. Check the spring force with tool (B). The spring force is 257 25 N (57.8 5.6 lb.). The length of spring under test force is 44.86 mm (1.766 in). The free length after test is 52.07 mm (2.050 in).4. Perform Steps 1 through 3 again for the remainder of the valves. The following steps are for the installation of the valves.5. Put clean engine oil on the valve stems. Install the valve, oil shield, spring (2) and rotocoil in the cylinder head. 6. Put tool (A) in position on the valve spring, and install the locks with tool (C).
Locks can be thrown from valve when the compressor is released if they are not in their correct position on valve stem. Personal injury can be the result if not carefully removed.
7. Remove tool (A), and hit the top of valve with a plastic hammer be sure the locks are in their correct position on valve.8. Do Steps 5 through 7 again for the remainder of the valves.End By:a. install spacer plate
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Put compression on valve spring (2) with tool (A), and remove locks (1).2. Remove tool (A), rotocoil, spring, valve stem oil shield and valve. Put identification marks on valves with respect to their location in the cylinder head. 3. Check the spring force with tool (B). The spring force is 257 25 N (57.8 5.6 lb.). The length of spring under test force is 44.86 mm (1.766 in). The free length after test is 52.07 mm (2.050 in).4. Perform Steps 1 through 3 again for the remainder of the valves. The following steps are for the installation of the valves.5. Put clean engine oil on the valve stems. Install the valve, oil shield, spring (2) and rotocoil in the cylinder head. 6. Put tool (A) in position on the valve spring, and install the locks with tool (C).
Locks can be thrown from valve when the compressor is released if they are not in their correct position on valve stem. Personal injury can be the result if not carefully removed.
7. Remove tool (A), and hit the top of valve with a plastic hammer be sure the locks are in their correct position on valve.8. Do Steps 5 through 7 again for the remainder of the valves.End By:a. install spacer plate