101695-3510 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016953510 6209711263

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101695-3510 1016953510

KOMATSU 6209711263 6209711263

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Cross reference number

ZEXEL 101695-3510 1016953510

KOMATSU 6209711263 6209711263

Zexel num

Bosch num

Firm num

Name

101695-3510

6209711263 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D95L * K

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

Overflow valve 131424-7420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

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 1100 1100 1100

Average injection quantity mm3/st. 74.6 73.6 75.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.2+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 12.5 11.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Rack difference from N = N1 (4)Rack difference between N = N2 and N = N3
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K=14 RAL=12.5+0.2mm N1=1100r/min N2=1100r/min N3=450r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
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aa=80mm
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a=34deg+-5deg b=19deg+-3deg c=32deg+-3deg

Timing setting

(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

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a=58deg+-3deg b=2deg+-30min

Information:

1. Loosen bolt (1).2. Loosen bolt (3).3. Push alternator (2) toward the engine to loosen the tension on the two alternator V-belts.4. Remove two alternator V-belts (4) from the alternator drive pulley and fan drive (6).5. Fasten a lifting strap and a hoist to fan drive (6). Remove four bolts (5) and the washers that hold the fan drive to the cylinder head assembly. Remove the fan drive. The weight of the fan drive is approximately 11 kg (25 lb). The following steps are for the installation of the fan drive.6. Be sure the mating surface on the cylinder head assembly and the mating surface on the fan drive support are thoroughly clean.7. Install the fan drive in the reverse order of removal.8. Adjust the tension of the alternator V-belts. See the topic "Alternator And Fan Drive Belts, Inspect/Adjust/Replace" in the 3114 & 3116 ATAAC Diesel Truck Engine Operation & Maintenance Manual, Form No. SEBU6723. Also, refer to the "Belt Tension Chart" in the 3114 & 3116 Diesel Truck Engines Specifications module, Form No. SENR6436.End By:a. install fan drive clutch assemblyDisassemble & Assemble Fan Drive
Start By:a. remove fan drive 1. Remove three bolts (6) and the washers. Access to bolts (6) can be made by rotating the fan pulley.2. Remove fan pulley assembly (2) from fan support (1).3. Remove two bolts (4) and thrust plate (5).4. Remove roller bearing assembly (8) and the bearing retainer from the fan pulley. Remove O-ring seal (7) from the bearing retainer. The following steps are for the assembly of the fan drive group.5. Be sure all parts of the fan drive group are thoroughly clean prior to assembly.6. Check the condition of O-ring seal (7) used in the bearing retainer. Also, check the condition of roller bearing assembly (8). If the components are damaged, use new parts for replacement.7. Install roller bearing assembly (8) in the bearing retainer. Be sure the lip seal in the roller bearing assembly is facing toward the bearing retainer.8. Install O-ring seal (7) in the bearing retainer. Put the bearing retainer and roller bearing assembly, as a unit, in position on pulley (2). Be sure the inner race of the roller bearing assembly in seated against the shoulder on the pulley.9. Install thrust plate (5) and two bolts (4).10. Put pulley assembly (2) in position in fan support (1). Install the three washers and bolts (6) that hold the unit together. Access to the mounting bolt holes can be made by rotating the fan pulley.11. Fill the bearing cavity in the fan drive with 30 g (1 oz) of 2S3230 Bearing Lubricant.End By:a. install fan drive