101495-3591 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014953591 6205711560


101495-3591 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101495-3591 1014953591
KOMATSU 6205711560 6205711560

Service parts 101495-3591 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101049-4150
3. GOVERNOR 105400-9731
4. SUPPLY PUMP 105220-5960
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105119-4250
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 19.6(200)
13. NOZZLE-HOLDER 105048-4450
14. NOZZLE 105017-9440
15. NOZZLE SET

Include in #1:

101495-3591 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101495-3591 1014953591
KOMATSU 6205711560 6205711560


Zexel num
Bosch num
Firm num
Name
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

Test data 101495-3591
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
----------
K=10 R1=(17.5)mm
----------

Speed control lever angle

Test data 101495-3591
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
----------
aa=910r/min bb=760r/min cc=60mm
----------
a=3deg+-5deg b=24deg+-5deg c=6deg+-5deg

Stop lever angle

Test data 101495-3591
N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb (stamp at delivery) (2)No return spring
----------
aa=3-0.5mm bb=0r/min
----------
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.
----------

----------

Timing setting

Test data 101495-3591
(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)-
----------
aa=10.3mm
----------
a=58deg+-3deg b=2deg+-30min




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