101495-3561 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953561 6205711550

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101495-3561 1014953561

KOMATSU 6205711550 6205711550

Cross reference number

ZEXEL 101495-3561 1014953561

KOMATSU 6205711550 6205711550

Zexel num

Bosch num

Firm num

Name

101495-3561

6205711550 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95LE-3

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 3.2 3.15 3.25

Rack position
After adjusting injection quantity. R=A

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 9.3

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 74 73 75

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Injection quantity adjustment_02

Adjusting point -

Rack position 7.7+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 13.5 12.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 52 72

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Rack cap

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 8.7

Boost pressure kPa 6.7 4 9.4

Boost pressure mmHg 50 30 70

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 8.9

Boost pressure kPa 14.7 12 17.4

Boost pressure mmHg 110 90 130

Boost compensator adjustment_03

Pump speed r/min 500 500 500

Rack position (9.3)

Boost pressure kPa 33.3 33.3 33.3

Boost pressure mmHg 250 250 250

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)Deliver without the torque control spring operating. (4)RACK CAP: R1 (5)Boost compensator stroke: BCL (6)Set idle sub-spring
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K=9 R1=(17.5)mm BCL=(0.6)mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=60mm
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a=2deg+-5deg b=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
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aa=1-0.5mm bb=0r/min
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a=27.5deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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0000001601 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
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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)B.T.D.C.: aa (5)After adjusting the injection quantity, adjust at rack position bb.
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aa=6deg bb=9.3mm
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a=58deg+-3deg b=2deg+-30min