Rating:
Information injection-pump assembly
ZEXEL
101600-3100
1016003100
KOMATSU
6742711120
6742711120
Service parts 101600-3100 INJECTION-PUMP ASSEMBLY:
1.
_
2.
FUEL INJECTION PUMP
4.
SUPPLY PUMP
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Cross reference number
ZEXEL
101600-3100
1016003100
KOMATSU
6742711120
6742711120
Zexel num
Bosch num
Firm num
Name
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
134424-4120
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
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
10.3
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
146
145
147
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
127
127
Boost pressure
mmHg
950
950
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.5+-0.5
Pump speed
r/min
460
460
460
Average injection quantity
mm3/st.
14.5
12.5
16.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder ON
*
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
9
Boost pressure
kPa
16
13.3
18.7
Boost pressure
mmHg
120
100
140
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
9.4
Boost pressure
kPa
38
35.3
40.7
Boost pressure
mmHg
285
265
305
Boost compensator adjustment_03
Pump speed
r/min
650
650
650
Rack position
10.6
Boost pressure
kPa
113
106.3
119.7
Boost pressure
mmHg
850
800
900
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)Adjust the secondary timing before adjusting the governor.
(4)When the hydraulic cylinder is OFF
(5)When hydraulic cylinder ON: P1
(6)Boost compensator stroke
(7)Rack difference between N = N1 and N = N2
(8)Main spring setting
(9)Set idle sub-spring
----------
K=11 P1=127+-10kPa(1.3+-0.1kgf/cm2) N1=900r/min N2=650r/min
----------
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K=11 P1=127+-10kPa(1.3+-0.1kgf/cm2) N1=900r/min N2=650r/min
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=1deg+-5deg b=26deg+-5deg
----------
----------
a=1deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=25deg+-5deg b=53deg+-5deg
----------
----------
a=25deg+-5deg b=53deg+-5deg
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(1)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(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)
(3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T3)
----------
T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=7.16~9.12N-m(0.73~0.93kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m) T3=2.9~4.4N-m(0.3~0.45kgf-m)
----------
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)R = cc
(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=7deg bb=0deg cc=10.3mm
----------
a=54deg42min+-3deg b=3deg30min+-30min
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aa=7deg bb=0deg cc=10.3mm
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a=54deg42min+-3deg b=3deg30min+-30min