101492-3820 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014923820 6204711441

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101492-3820 1014923820

KOMATSU 6204711441 6204711441

Service parts 101492-3820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8320

3. GOVERNOR 105400-6131

4. SUPPLY PUMP 105220-5280

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5631

11. Nozzle and Holder 6207-11-3102

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3300

14. NOZZLE 105017-1450

15. NOZZLE SET

Include in #1:

101492-3820 as INJECTION-PUMP ASSEMBLY

106682-9130 as _

Cross reference number

ZEXEL 101492-3820 1014923820

KOMATSU 6204711441 6204711441

Zexel num

Bosch num

Firm num

Name

101492-3820
101495-3030

6204711441 KOMATSU

INJECTION-PUMP ASSEMBLY
4D95L * 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

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 1-2-4-3

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.6

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 36.5 35.5 37.5

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 375 375 375

Average injection quantity mm3/st. 6.2 5.2 7.2

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 CAP: R1 (3)The torque control spring must does not have a set force. (4)Idle sub spring setting: L1. (5)Rack difference between N = N1 and N = N2
----------
K=12++ R1=(17.5)mm L1=7.5-0.5mm N1=850r/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=(9deg)+-5deg b=(22deg)+-5deg c=(6deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=4deg+-5deg b=53deg+-5deg

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)-
----------

----------
a=59deg36min+-3deg b=0deg24min+-30min