101495-3590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953590 205711560

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101495-3590 1014953590

KOMATSU 205711560 205711560

Cross reference number

ZEXEL 101495-3590 1014953590

KOMATSU 205711560 205711560

Zexel num

Bosch num

Firm num

Name

101495-3590

205711560 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95LE-3 K

101495-3590
101495-3591

6205711560 KOMATSU

INJECTION-PUMP ASSEMBLY
S4D95LE-3 * 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 3.2 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 10.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 84.5 83.5 85.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 13.5 12.5 14.5

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)Tolerance for racks not indicated: +-0.05mm. (3)RACK CAP: R1 (4)Set idle sub-spring
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K=10 R1=(17.5)mm
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Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)When pump speed set at bb (3)Stopper bolt setting (4)Use the hole above R = cc
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aa=910r/min bb=760r/min cc=60mm
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a=3deg+-5deg b=24deg+-5deg c=6deg+-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=3-0.5mm bb=0r/min
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a=22.5deg+-5deg b=(50deg)

0000001501 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)After adjusting the injection quantity, adjust at rack position aa. (5)-
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aa=10.3mm
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a=58deg+-3deg b=2deg+-30min