101601-3340 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016013340 6138721980


 

Information injection-pump assembly

ZEXEL 101601-3340 1016013340
KOMATSU 6138721980 6138721980
101601-3340 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101601-3340 1016013340
KOMATSU 6138721980 6138721980


Zexel num
Bosch num
Firm num
Name
101601-3340 
101601-3341 
 
6138721980  KOMATSU
INJECTION-PUMP ASSEMBLY
S6D110 *

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   10
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   77 76 78
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the lever   *
Boost pressure kPa   40 40
Boost pressure mmHg   300 300
Injection quantity adjustment_02
Adjusting point   B
Rack position   8+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   12.3 11.1 13.5
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   11.1
Boost pressure kPa   13.3 9.3 17.3
Boost pressure mmHg   100 70 130
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   11.6
Boost pressure kPa   26.7 26.7 26.7
Boost pressure mmHg   200 200 200
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   1100
Advance angle deg.   2.8 2.3 3.3
Timer adjustment_05
Pump speed r/min   -
Advance angle deg.   5 4.5 5.5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101601-3340
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Boost compensator stroke (3)Rack difference between N = N1 and N = N2 (4)Rack difference between N = N3 and N = N4
----------
K=9 N1=1100r/min N2=750r/min N3=1100r/min N4=400r/min
----------

Speed control lever angle

Test data 101601-3340
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=2deg+-5deg b=27deg+-5deg

Stop lever angle

Test data 101601-3340
N:Pump normal S:Stop the pump. (1)At shipping (2)Pump speed aa, rack position bb (3)Stopper bolt setting
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

Test data 101601-3340
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

The problems in this chart are problems that do come about and are normally called "low power." These problems are not necessarily more common than engine problems, but they are possible problems which you need to read and check before an engine is disassembled.Read all of the items but make sure the first four are checked completely before making any engine test.Recommended Procedure
1. Tachometer Error ... To check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is bad, make repairs as necessary or install a new tachometer.2. Engine Operated at High Altitude ... Less oxygen at higher altitudes causes the engine horsepower to go down. There is no effect on the 225 horsepower engine for the first 2280 m (7500 ft) above sea level of operation. There is no effect on the 235 and 250 horsepower engines for the first 1524 m (5000 ft) above sea level of operation. See the Fuel Setting And Related Information Fiche for the correct fuel setting for the higher altitude of operation.3. Brakes Do Not Completely Release ... Check the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack, the wheels must have free rotation when turned by hand.4. Vehicle Operated in Too High a Gear ... If the operator does not shift the truck correctly, or operates the truck in a "lug" condition (using the truck in too high a gear for engine rpm to go up as accelerator pedal is pushed farther down, or using the truck in a gear where engine rpm goes down with accelerator pedal at maximum travel), poor vehicle performance is the result.5. Extra Engine Driven Equipment ... Air compressors, hydraulic pumps, alternators and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine.6. Speedometer Error ... A bad speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem.7. Speeds Too High ... The need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Application personnel can give you the horsepower necessary for different vehicle designs at different speeds.8. Overload on Vehicle ... Application personnel can give you the horsepower needs for different vehicles.9. High Moving Resistance ... Soft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be

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