101601-3110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016013110 6138721550

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-3110 1016013110

KOMATSU 6138721550 6138721550

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Service parts 101601-3110 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2750

3. GOVERNOR 105410-7290

4. SUPPLY PUMP 105210-4600

5. AUTOM. ADVANCE MECHANIS 105614-3110

6. COUPLING PLATE 105662-0810

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6000

11. Nozzle and Holder 6138-12-3100

12. Open Pre:MPa(Kqf/cm2) 24.5{250}

13. NOZZLE-HOLDER 105031-4480

14. NOZZLE 105015-5680

15. NOZZLE SET

Include in #1:

101601-3110 as INJECTION-PUMP ASSEMBLY

101692-3910 as _

Cross reference number

ZEXEL 101601-3110 1016013110

KOMATSU 6138721550 6138721550

Zexel num

Bosch num

Firm num

Name

101601-3110
101601-3550

6138721550 KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D110 * 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 1-5-3-6- 2-4

Pre-stroke mm 4 3.95 4.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position R1(10)

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 73 72 74

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13 11.8 14.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Rack difference between N = N1 and N = N2
----------
K=8 N1=500r/min N2=330r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=6deg+-5deg b=21deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(0deg)

Information:

preparatory step: a) remove air compressor1. Disconnect the water pump outlet line (1).2. Disconnect the water temperature regulator water bypass line (2).3. Remove the water pump (3).Install Water Pump
1. Position the water pump on the engine.2. Connect the water temperature regulator bypass line.3. Connect water pump outlet line.concluding step: a) install air compressorDisassemble Water Pump
preparatory step: a) remove water pump 1. Remove the water pump cover (1). 2. Loosen the impeller retaining nut flush with the end of the pump shaft. Install tool setup (A) and separate the impeller from the shaft.3. Remove the tool setup and impeller. 4. Remove the bearing cage retaining nuts (3).5. Remove the bearing cage and shaft assembly (2) from the pump housing.6. Remove the ceramic seal and oil seal from the pump housing.7. Remove the bearing retaining nut and spacer from the shaft assembly. 8. Press the gear and bearings from the shaft.Assemble Water Pump
1. Heat the bearings and gear to 300°F (149°C). 2. Install one bearing and its bearing cage (5) on the shaft. Install the gear (4) on the shaft with the concave side towards the bearing cage.3. Install the remaining bearing (3), spacer (2), lock and retaining nut (1). 4. Install the oil seal in the pump housing using tool setup (A). Install the oil seal (8) as shown. 5. Install the ceramic ring (11) and rubber seal (12) in the pump housing with the polished side of the ceramic ring toward the impeller.6. Position the bearing and shaft assembly in the pump housing. Install the bearing cage retaining nuts (7). Lubricate the oil seal lip lightly with SAE 30 engine oil before installing the shaft assembly.7. Install the carbon portion of the seal and the spring on the shaft.8. Install the impeller (10) and retaining nut (6). Tighten the nut to 30 5 lb. ft. (4,1 0,7 mkg) plus the amount required to align on cotter pin hole. Install the cotter pin and bend the legs of the pin around the nut.9. Install the water pump cover (9).concluding step: a) install water pump