Information injection-pump assembly
ZEXEL
101609-3550
1016093550
Rating:
Cross reference number
ZEXEL
101609-3550
1016093550
Zexel num
Bosch num
Firm num
Name
101609-3550
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
131424-3420
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
1-5-3-6-
2-4
Pre-stroke
mm
2.5
2.45
2.55
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
10.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
134.5
133.5
135.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11
10
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
125
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Stop lever at stopping (with the speed lever at full)
(5)Set idle sub-spring
(6)Adjust the secondary timing before adjusting the governor.
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=23deg+-5deg
----------
----------
a=3deg+-5deg b=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min
Information:
Problem
The number-two fuel injection line on certain 775B Trucks and 992D Loaders may fail.
Affected Product
Model & Identification Number
775B (7XJ76-102)
992D (7MJ50-121, 7MG123)
Parts Needed
2 - 5P4939 Screw Assembly1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See attached rework procedure.
Service Claim Allowances
This is a .5-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
1. Using 2 - 5P4939 Screw Assemblies, install 1 - 9Y3357 Clamp and 1 - 1029228 Clamp Assembly on the number 2 and number 6 fuel lines. Tighten the screws to a torque of 2.25 .25 Nm (20 Lb. in.). Refer to Illustration 1.2. Remove the existing 2 - 1W9169 Clamps, 2 - 9N3388 Screws, 2 - 1W9167 Clamp Assemblies, 2 - 4B4274 Washers and 1 - 9Y7524 Plate on the number 2 and number 8 fuel lines. Refer to Illustration 2.
Illustration 1
Illustration 2
The number-two fuel injection line on certain 775B Trucks and 992D Loaders may fail.
Affected Product
Model & Identification Number
775B (7XJ76-102)
992D (7MJ50-121, 7MG123)
Parts Needed
2 - 5P4939 Screw Assembly1 - 9Y3357 Clamp1 - 1029228 Clamp AssemblyAction Required
See attached rework procedure.
Service Claim Allowances
This is a .5-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
1. Using 2 - 5P4939 Screw Assemblies, install 1 - 9Y3357 Clamp and 1 - 1029228 Clamp Assembly on the number 2 and number 6 fuel lines. Tighten the screws to a torque of 2.25 .25 Nm (20 Lb. in.). Refer to Illustration 1.2. Remove the existing 2 - 1W9169 Clamps, 2 - 9N3388 Screws, 2 - 1W9167 Clamp Assemblies, 2 - 4B4274 Washers and 1 - 9Y7524 Plate on the number 2 and number 8 fuel lines. Refer to Illustration 2.
Illustration 1
Illustration 2
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Komatsu
Komatsu
101609-3550
INJECTION-PUMP ASSEMBLY