101609-3860 ZEXEL test values diesel fuel-injection equipment 22/06/21 13:10:06 Page 1

ZEXEL Ass'y No. 101609-3860

Bosch Ass'y No. F 019 Z20 032
Bosch Typecode
Engine Type SAA6D102E-2
Manufacturer KOMATSU
Edition date 14/04/11 (2)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113 or {SAEJ96
7d}
1404 Test oil
P 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
P Opening pressure MPa 17.2
P Opening pressure kgf/cm2 175
Injection pipe mm 6-2-600
Outer diameter - inner diameter - length (mm)
Overflow valve 131424-3420
P Overflow valve opening pressure kPa 255 221 289
P Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95
P Tester oil delivery pressure kPa 255 255 255
P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Direction of rotation (viewed from drive side) R
Right
P Injection order 1-5-3-6-2-4
S Pre-stroke mm 2.6 2.55 2.65
S Rack position R=A
After adjusting injection quantity.
P Beginning of injection position NO.1
Drive side
S Difference between angles 1 deg. 60 59.5 60.5
Cal 1-5
S Difference between angles 2 deg. 120 119.5 120.5
Cal 1-3
S Difference between angles 3 deg. 180 179.5 180.5
Cal 1-6
S Difference between angles 4 deg. 240 239.5 240.5
Cyl.1-2
S Difference between angles 5 deg. 300 299.5 300.5
Cal 1-4
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position 10.6
P Pump speed r/min 1000 1000 1000
S Average injection quantity mm3/st. 127.5 126.5 128.5
S Max. variation between cylinders % 0 -2.5 2.5
P Basic *
P Fixing the lever *
P Boost pressure kPa 140 140
P Boost pressure mmHg 1050 1050
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 7.2+-0.5
P Pump speed r/min 450 450 450
S Average injection quantity mm3/st. 13 12 14
S Max. variation between cylinders % 0 -15 15
P Fixing the rack *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
101609-3860 ZEXEL test values diesel fuel-injection equipment 22/06/21 13:10:06 Page 2

CAT Designation Unit Set value min. max. Actual values OT

P Adjusting point F
P Rack position 11.3++
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 105 100 110
P Fixing the lever *
P Boost pressure kPa 153 153
P Boost pressure mmHg 1150 1150
P Rack limit *
2.3 Governor adjustment
Name

K=10 N:Pump speed

BCL=2.2+-0.1mm R:Rack position (mm)
N1=1000r/min (1)Target notch: K
N2=1000r/min (2)Tolerance for racks not indicated: +-0.05mm.
N3=750r/min (3)Because the specifications are for the hydraulic actuator to be normally ON, it is not necessary
to supply hydraulic pressure. (The eye bolt, however, must be installed.)
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Rack difference from N = N1
(7)Rack difference between N = N2 and N = N3
2.4 Boost compensator adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Rack position 8.9
S Boost pressure kPa 20 13.3 26.7
S Boost pressure mmHg 150 100 200
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Rack position 10.2
S Boost pressure kPa 80 76 84
S Boost pressure mmHg 600 570 630
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Rack position 11.1
S Boost pressure kPa 127 127 127
About
S Boost pressure mmHg 950 950 950
About

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.5 Speed control lever angle

Name
a=11deg+-5deg
b=30deg+-5deg

F:Full speed
I:Idle
(1)Stopper bolt setting
2.6 Stop lever angle
Name
a=0deg+-5deg
b=53deg+-5deg

N:Pump normal
S:Stop the pump.
(1)No return spring
2.7 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.7.1 Additional device 1

Name TAMPER PROOF

T1=7.16~9.12N-m(0.73~0.93kgf-m) Tamperproofing-equipped boost compensator cover installation procedure

T2=2.9~4.4N-m(0.3~0.45kgf-m) (1)After adjusting the governor and the boost compensator, tighten to the specified torque to brea
T3=2.9~4.4N-m(0.3~0.45kgf-m) k off the bolt heads.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to brea
k off the bolt heads.
(Tightening torque T = T2)
(3)After adjusting the governor and the boost compensator, tighten to the specified torque to brea
k off the bolt heads.
(Tightening torque T = T3)
2.7.2 Additional device 2
Name I/P WITH LOAD PLUNGER ADJ

h=2.6mm Adjusting procedure for load plunger equipped pump with RSV (cam lock) governor (see service i
c=5deg15min+-30min nformation S.I. 434 for details).
At cam lift h+-0.01, set the camshaft c deg from the * mark in accordance with the timing adjustm
ent procedure.
2. Align the flyweight's timing tooth position and the lock pin groove and then fully tighten the flyw
eight to the camshaft. Then, remove the lock pin.
3. Adjust the maximum variation between cylinders and injection quantity.
4. Adjust using the pre-stroke adjusting shim so that the pre-stroke value is the value for 4/4 load
(standard point A).
5. After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation b
etween cylinders are as specified.
6. At delivery, again fix the flyweight using the lock pin.

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.8 Timing setting

Name
a=55deg18min+-3deg
b=55deg18min+-3deg13min48sec
c=5deg15min+-30min

aa=10.5deg (1)Pump vertical direction

bb=0deg (2)Key groove position for No. 1 cylinder's cam lift h = cc (at BTDC aa).
cc=2.6+-0.01mm (3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity
adjustment).
(4)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).
(5)B.T.D.C.: aa

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)